Most facilities don’t schedule a dust collection audit because everything is running perfectly. They call when differential pressure won’t come down, filters are failing too soon, emissions are increasing, production is being affected, or someone simply asks, “Why is our dust collector becoming a constant headache?”
That’s where a good inspection makes all the difference. In this interview, Dominick Dal Santo, Sales Director and Technical Advisor at Baghouse.com, takes us behind the scenes of a professional dust collection audit. He explains what our team looks for and the kinds of problems we uncover every day.
— What Happens During One of Our Inspections?
Dominick: “Before we ever arrive on site, we ask customers to send us as much information as they have about their dust collectors. We want to understand what problems they’re experiencing and what they hope to accomplish.
Once we’re at the plant, we inspect each system, review differential pressure, cleaning systems, fans, ductwork, controls, airlocks, and maintenance practices. We also spend time talking with maintenance, operations, and environmental personnel because understanding how the system is actually being used is just as important as inspecting the equipment itself.
Before we leave, we review our findings with the customer and then prepare a detailed, easy-to-read report with both short-term and long-term recommendations.”
â–¶ Watch his full answer below.
— What Kind of Problems Can an Audit Uncover?
Dominick: “Some of the biggest problems we find are things plants don’t even realize are happening. We frequently discover inaccurate differential pressure readings, improperly sized filters, incorrect filter media, plugged hoppers, dust buildup inside ductwork, and cleaning systems that aren’t operating correctly.
Sometimes the equipment itself isn’t the problem at all. The biggest issue is simply that people have been taught to operate the system the wrong way, and those misunderstandings have been passed down for years.”
â–¶ Watch his full answer below.
— Why Are Baghouse.com Audits Different?
Dominick: “Some companies call an inspection a quick sales visit, while others produce hundreds of pages of engineering data that’s difficult for anyone to use. We try to find the balance between those two extremes.
Our inspections are practical, thorough, and focused on solving problems. Our reports are detailed but concise, written so operators, maintenance teams, engineers, managers, and environmental personnel can all understand exactly what we found and what we recommend.”
â–¶ Watch his full answer below.
— Who Performs the Inspection?
Dominick: “When you schedule a Baghouse.com audit, you’re getting one of our dust collection experts. We send engineers, technical leads, or experienced system specialists—not someone who’s simply there to sell equipment.
Our goal is to understand your system, troubleshoot problems with you, and discuss both today’s challenges and your future expansion plans.”
â–¶ Watch his full answer below.
— How Can an Audit Help Increase Dust Collector Efficiency Without Major Spending?
Dominick: “We always try to improve what you already have before recommending major capital investments. Sometimes it’s as simple as upgrading to a differential-pressure controller, improving how spare parts are managed, refurbishing an older collector, or making ductwork modifications. Those kinds of improvements can extend filter life, reduce compressed air consumption, improve airflow, and significantly lower operating costs without replacing the entire system.”
â–¶ Watch his full answer below.
— How Can an Audit Help with Combustible Dust or OSHA/NFPA Compliance?
Dominick: “Many facilities know they handle combustible dust, but they often have gaps in their protection strategy. During an audit, we’re evaluating explosion isolation, explosion venting, spark detection, rotary airlocks, return-air systems, and operational practices.
We also look for practical hazards like dust accumulating in hoppers or ductwork. Sometimes improving how the system operates does just as much for safety as installing new protection equipment.”
â–¶ Watch his full answer below.
— Can You Share a Case Study Where an Audit Made a Difference?
Dominick: “One of my favorite examples is United States Gypsum. At one facility, we found they had an unused baghouse sitting nearby while another system struggled because of poor ductwork. Instead of recommending a new collector, we redesigned the ductwork, refurbished the existing unit, converted it to pleated filters, and optimized the cleaning controls. They solved the problem while avoiding a major capital expense. We also helped them eliminate unnecessary pulse cleaning on dozens of collectors, saving a tremendous amount of compressed air.”
â–¶ Watch his full answer below.
— What Do We Include in the Final Report?
Dominick: “Our reports clearly summarize what we found, include photographs of the equipment, prioritize our recommendations, and explain practical solutions for each issue.
We also include appendices with technical guidance, equipment proposals, and quotations whenever appropriate, so customers immediately understand both the recommendations and what they’ll involve.”
â–¶ Watch his full answer below.
— What Do Companies Need to Prepare for a System Audit?
Dominick: “Most companies are surprised by how little preparation is actually required. We simply need access to the dust collectors while they’re operating normally, someone who can walk the plant with us, maintenance records, drawings, specifications, and the opportunity to talk with plant personnel.
In most cases, we don’t need confined space entry or lengthy shutdowns. With that information alone, we’re able to diagnose the vast majority of the issues we encounter.”
â–¶ Watch his full answer below.
Final Thoughts
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Every dust collection system has opportunities for improvement—you just have to know where to look.
As Dominick explains throughout this interview, a professional audit will help you understand how your current system is performing, identify hidden problems, improve reliability, reduce operating costs, and help your facility make smarter decisions for the future.Â
Dust Collection Expert, Technical Writer & Editor at Baghouse.com
Andy Biancotti believes that knowledge is one of the best investments any company can make. As Editor and Marketing Manager at Baghouse.com, he enjoys interviewing engineers, technicians, and customers to capture the real-world lessons behind successful dust collection projects and turn them into practical resources that others can learn from. With more than two decades of experience in industrial maintenance, operations, and technical communication, his goal is simple: help people better understand their systems so they can work safer, smarter, and more efficiently.
