Industrial Dust Collectors Archives - IVI, Inc. /category/industrial-dust-collectors/ Custom Industrial Ventilations Systems Tue, 16 Jun 2026 16:58:02 +0000 en-US hourly 1 https://wordpress.org/?v=6.9.4 /wp-content/uploads/2020/08/Favicon-6.png Industrial Dust Collectors Archives - IVI, Inc. /category/industrial-dust-collectors/ 32 32 Baghouse replacement /replacing-an-aging-baghouse/ Sat, 23 May 2026 20:51:35 +0000 /?p=11475 When to move on from a dust collector The industrial baghouse manufacturing landscape is always evolving. Whether you own an Pneumafil dust collector, MikroPul baghouse, Pangborn dust collector or a custom dust collection system from IVI, Father Time is undefeated. Is it time to replace your aging baghouse? Even if you’re keeping a close eye...

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When to move on from a dust collector

The industrial baghouse manufacturing landscape is always evolving. Whether you own an Pneumafil dust collector, MikroPul baghouse, Pangborn dust collector or a custom dust collection system from IVI, Father Time is undefeated.

Is it time to replace your aging baghouse?

Even if you’re keeping a close eye on common issues in baghouse maintenance, an aging baghouse can expose your operation to employee health and safety risks, production shutdowns, regulatory compliance issues and more. And, if you’ve fallen behind on baghouse maintenance—and plugged ductwork, leaking pulse valves, damaged bags or other problems persist—it’s likely accelerating baghouse wear and tear and the risk your company is taking. If your dust collection system brand has changed manufacturers, regular maintenance becomes even more critical to avoid significant issues.

Aging baghouse indicators that affect all baghouse brands

While the lifespan of a baghouse is influenced by environmental conditions, particulate removal demands and maintenance, a typicaal baghouse lifespan is 20 years or longer. Whether you own a Pneumafil baghouse, MikroPul dust collector, Pangborn baghouse or һݶcustom solution that is more than two decades old, these indicators can help you assess whether it may be reaching its end of life.

  • Overall deterioration: You may see rust, cracks, corrosion and other deterioration to your industrial dust collection system, hear unexpected noises or experienced reduced efficiency in particulate removal. This deterioration may indicate it is time for a baghouse replacement.
  • Replacement parts access: Common parts that need replacing include bag filters, timer boards and diaphragm valves. Changes in the baghouse industry can lead to availability issues for critical system components for baghouse brands that are no longer manufactured. If finding baghouse parts or supplies for your aging baghouse is becoming more difficult, it may be time to consider a baghouse replacement.
  • Maintenance costs: If your baghouse has been in use for decades, the costs to keep it running effectively and efficiently may add up. If maintenance costs are on the rise, a baghouse replacement may be needed.

Explore replacement options before a problem risks employee health and safety or causes a shutdown, further cutting into your bottom line.

Current system evaluation

If questioning whether a replacement is the best path forward, the first step is to evaluate the current dust collection system—whether it be an IVI, Mikropul, Pangborn or Pneumafil baghouse—or another brand manufactured during the last century. An evaluation can help you determine your baghouse’s current capacity and whether modifications can be made or a full replacement is necessary.

When replacement is needed

If modifications can extend the life of your baghouse, the һݶteam can explore the available options. If not, our experienced team can provide turnkey solutions. Across any industry and ranging from 50 to 1 million cubic feet per minute, the һݶteam is ready to design and engineer, fabricate and install a new long-lasting industrial baghouse solution for you.

Explore Baghouse Replacement Options

MIKROPUL is a registered trademark of MENARDI MIKROPUL LLC, 4404-A CHESAPEAKE DR, CHARLOTTE, NORTH CAROLINA UNITED STATES 28216

PANGBORN is a registered trademark of PANGBORN LLC, 4630 COATES DRIVE, FAIRBURN, GEORGIA UNITED STATES 30213

PNEUMAFIL is a registered trademark of NEDERMAN CORPORATION, 4404 CHESAPEAKE DRIVE, CHARLOTTE, NORTH CAROLINA UNITED STATES 28216

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How Does a Baghouse Dust Collector Work? /how-does-a-baghouse-dust-collector-work/ Thu, 23 Oct 2025 18:28:58 +0000 /?p=11251 Baghouse Basics An industrial baghouse dust collector, when paired with an industrial blower, pulls in air and cleans dust, dirt and other particulate matter generated by manufacturing processes from it. As part of an industrial dust collection system, baghouses help provide workers with a safer environment by improving air quality, reducing fire and explosion hazards,...

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Baghouse Basics

An industrial baghouse dust collector, when paired with an industrial blower, pulls in air and cleans dust, dirt and other particulate matter generated by manufacturing processes from it.

As part of an , baghouses help provide workers with a safer environment by improving air quality, reducing fire and explosion hazards, removing hazardous particulates and improving productivity through ease-of-maintenance. Baghouse dust collectors also prevent particulate matter from entering the atmosphere. How does a baghouse system work? That’s where engineering and design play a key role.

How a Baghouse Works: Baghouse Dust Collector Working Principles

While they’re built in different designs and sizes, all baghouses essentially operate in the same way. Air from an industrial environment enters a baghouse through an air inlet or duct. The baghouse contains rows of fabric tube-shaped bags, which filter the particulate matter and other contaminants from the air. As the air passes through the fabric, dust and other particles are separated from the air. Smaller particulates collect on the bags and larger particulates fall into a hopper below.

baghouse graphic

After the air is filtered, it moves out of the baghouse through a clean air outlet or duct. A cleaning mechanism or system (a few examples of these mechanisms are outlined below) also works to remove built-up particulate from the fabric bags, causing it to fall into the hopper below.

Baghouse Dust Collector Types

While baghouse dust collector systems all work in the same basic way, there are a few different varieties.

  • Reverse air dust collectors, for example, use a low-pressure reversed flow to backflush the air through the filter bags.
  • Pulse jet dust collectors, meanwhile, use puffs of pressurized air, pulsing air through the filters.
  • Shaker dust collectors are used in facilities where compressed air is impractical, like mines. These dust collectors use mechanics to shake dust from the filter bags and are common for certain particulates more easily separated from filters, like chicken dander and feathers.

һݶand Baghouse Dust Collectors

һݶhas designed, , and hundreds of baghouse dust collection systems across a variety of industries, including mining, pulp and paper, foundries and beyond. Each system is designed to specifically address particle types, explosion protection guidelines, regulatory emission rates and much more. Whether built for fumes, fine or heavy dust, each custom-engineered baghouse provides cleaner and safer facilities and workplaces.

How Do Baghouses Work For You?

Now with an understanding of how a baghouse works, you can decide whether an industrial baghouse dust collector is the solution for you.

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Baghouse Troubleshooting /baghouse-troubleshooting-understanding-problems-and-finding-solutions/ Thu, 23 Oct 2025 12:05:17 +0000 /?p=11241 Understanding Problems and Finding Solutions A fully functional baghouse dust collector is important for the safety of your employees and your business. When problems arise—even small ones—it puts your operation at risk of shutdowns, exposes you to regulatory citations and can impact your bottom line. Fortunately, some common problems are simple to diagnose and have...

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Understanding Problems and Finding Solutions

A fully functional baghouse dust collector is important for the safety of your employees and your business. When problems arise—even small ones—it puts your operation at risk of shutdowns, exposes you to regulatory citations and can impact your bottom line. Fortunately, some common problems are simple to diagnose and have affordable solutions. Here’s a guide to baghouse troubleshooting.

Common Baghouse Problems

High Differential Pressure and/or Short Bag Life

Experiencing high differential pressure or unexpectedly short bag life are common issues in baghouse systems.

Probable Cause: Maintenance Problems

The most common source of problems with baghouses arise from poor bag installation, a faulty differential pressure gauge, leakage through the discharge device, valve and solenoid failures, wet or oily compressed air, a faulty timer or wet bags.

Probable Cause: Design Problems

Design-related issues are a potential culprit when encountering high differential pressure or reduced bag life. Possibilities include high dust loading, high air-to-cloth ratio, high can velocity, improper fabric or surface treatment or an improper or undersized discharge device.

Probable Cause: Operational Problems

During the baghouse troubleshooting process, consider whether operational issues such as improper start-up sequence, improper damper settings or high moisture content and lower temperature in the gas stream may be the cause.

Low Differential Pressure

Low differential pressure in a baghouse signals underlying issues that might affect performance.

Probable Cause: Operational Problems

Operational issues can often result in low differential pressure, primarily due to over-cleaning of bags due to excessive pulse pressure or pulse frequency.

Probable Cause: Maintenance Problems

Regular maintenance is key to ensuring consistent differential pressure. Look for plugged lines or broken or uncoupled manometer lines.

Dust Emission to Atmosphere

Baghouse dusting can reduce efficiency and risk non-compliance.

Probable Cause: Design Problems

Design flaws can lead to baghouse dusting issues. In baghouse troubleshooting, look for an extremely high air-to-cloth ratio, poor seal arrangement, extremely fine dust (or very fine spherical particles), the wrong fabric or surface treatment or the wrong bag size.

Operational Problems

Operational settings and procedures can also contribute to baghouse dusting. Consider whether a wrong damper setting or poor start-up procedure are the culprit.

Maintenance Problems

On the maintenance side, several issues can lead to baghouse dusting. They include poor bag installation or seal, tubesheet leaks, holes in bags or bad diaphragms or solenoids.

Puffing Back

Puffing back is when dust re-enters the dirty air stream.

Probable Cause: Operational Problems

If operational causes lead to puffing back, it’s likely from a high pressure drop across the baghouse, low system fan speed or improper duct balancing.

Maintenance Problems

Plugged duct lines and poor hood designs are two maintenance causes to consider.

Excessive Hopper Build-up

Probable Cause: Design Problems

Among the reasons design could play a role in excessive build-up in the hopper: a too-slow or faulty rotary air lock, the outlet is too small, there’s an improper discharge device or improper hopper slope.

Probable Cause: Operational Problems

The failure to initiate the discharge device prior to start-up or operate the discharge device after the fan has shut down may cause excessive build-up in the hopper.

Probable Cause: Maintenance Problems

Maintenance issues could lead to excessive hopper build-up when the rotary air lock needs rebuilding, there’s excessive rust or build-up on the hopper walls or material has become packed and won’t flow.

Low Dust Discharge

A few operational or maintenance issues can lead to the insufficient removal of collected dust from the baghouse hopper or discharge system.

Probable Cause: Operational Problems

Leakage at discharge points and re-entrainment of dust on filter bags can be operational causes of low dust discharge.

Probable Cause: Maintenance Problems

A malfunction of the discharge valve, screw conveyer or material transfer equipment might be an issue. Or re-entrainment of dust within the collector could be due to possible leaks in the hopper.

Holes in Bags

There are many potential causes when holes are found in bags.

Probable Cause: Design Problems

Improper fabric, an inlet abrasion from excessive inlet velocity or turbulence or bags rubbing together a warped tubesheet could create holes.

Probable Cause: Operational Problems

Too-high inlet temperature, sparks in the inlet gas stream, or high moisture mixed with moderate heat causing hydrolysis are possible culprits.

Probable Cause: Maintenance Problems

A few maintenance issues need investigating, including the failure to clean the tubesheet (leading to abrasion from the inside), bent cages rubbing against the walls or each other, excessive pulse cleaning, bags damaged during installation, broken cage wires, or improper bag installation.

Loud or Unusual Noises

Noises can cause headaches in more ways than one. Either maintenance issues or, in the case of a pulse jet baghouse, the pulse system may be to blame.

Probable Cause: Maintenance Problems

Vibrations, banging of moving parts or squealing of belt drives can cause excessive noise. Addressing these maintenance issues will generally address the noise issue.

Probable Cause: Pulse System

Unexpected noises can be caused by valves not properly pulsing or a compressed air leak in a pulse jet baghouse.

Baghouse Corrosion

When you see signs of corrosion, here’s where to begin your baghouse troubleshooting.

Probable Cause: Operational Problems

Dew point excursions and improper shutdowns and startups can lead to corrosion.

Probable Cause: Maintenance Problems

Improper paint, material, or application, improper insulation and emission of nearby equipment are also common corrosion causes.

Baghouse Troubleshooting: When to Seek Outside Support

Sometimes in-house baghouse troubleshooting can only get you so far. Whether you need help identifying the root problem or know what the problem is but need help to address it, һݶcan help. When problems persist or maintenance is needed, contact IVI’s expert team to schedule baghouse troubleshooting help, repair or service.

Baghouse Troubleshooting

If differential pressure, puffing back, corrosion or other baghouse issues have you concerned, contact һݶtoday.

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Baghouse Leak Detection System [Video] /baghouse-leak-detection/ Thu, 23 Oct 2025 11:50:45 +0000 /?p=11239 һݶEngineers Explain the Importance of Baghouse Leak Detection Testing Transcript Who needs to do a baghouse leak detection test? Anyone who owns or operates a dry-type dust collector, such as a baghouse or cartridge collector, needs to do a baghouse leak detection test. How often do you need to do a leak detection test?...

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һݶEngineers Explain the Importance of Baghouse Leak Detection Testing

Transcript

Who needs to do a baghouse leak detection test?

Anyone who owns or operates a dry-type dust collector, such as a baghouse or cartridge collector, needs to do a baghouse leak detection test.

How often do you need to do a leak detection test?

Leak detection tests should be done every time you do a filter change. Some regulatory requirements dictate that leak detections need to be done on an annual basis, or a six-month basis, and then also any time you suspect a leak in your system, a leak test is good to help diagnose where that leak is coming from.

What are the risks of not doing a leak detection test?

Filter changes are a fairly expensive operation, so not doing a leak detection test could mean all the money you spent on that filter change is thrown out because of an improper installation.

Additional reasons to conduct these tests, and reasons to mitigate the risk by doing them, is because a hole in your filter could mean a failure to comply with regulatory requirements.

Step by step: The baghouse leak detection system

Before conducting the test, you’re going to want to consult your safety department to ensure that all lockout, tagout and confined space procedures are followed for this procedure.

Step one is we are going to be inserting the dye into the system. In this case, we’re going to insert the dye (or baghouse leak detection powder) into the hopper here. [In your system, dye may need to be inserted into the collection ductwork.]

Now that our dyes have been added, we’ve ensured that our filters are evenly coated, we are going to do an inspection of the clean-air side of our bags to ensure that none of the dye made it through or around the filters and ensure we have a nice, good installation.

Now we’re up on the clean-air section of the baghouse. Because this thing is so small, we can actually lift off the entire roof of it. So first I’m going to do a quick initial inspection to see if I see any dye. Usually, if there’s a major leak, you’ll see it instantaneously. But now that we don’t see any, we’re going to actually do the blacklight portion and turn off the lights and see what we can see.

All right. Since in our test we didn’t see any leaks, we wanted to show you we scattered some dye around here and wanted to show you what it would look like if there was a leak and how vividly that shows up.

Whether you purchased your baghouse from һݶor not, һݶcan assist in these leak detection tests and help diagnose problems and come up with long-term solutions.

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Baghouse Manufacturers Show Baghouse Industrial Assembly [VIDEO] /ivi-baghouse-industrial-ventilation-installation-video/ Fri, 19 Jan 2024 18:55:40 +0000 /?p=10590 Transcript һݶ– 100,000 CFM Dust Collector Assembly The ProjectFoundry Application to Mitigate Dust Exposure6 Months Before: Design and Engineering4 Months Before: Fabrication1 Week Before: 3-Person Crew Site Prep The Crew60 Years Crew ExperienceSix-Person Installation Team The InstallationBaghouse Assembly Built Up from HopperCustom Structural Steel and StaircasePre-Assembled Catwalk and Walk-In Plenum Access Final Product65-Foot Tall...

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Transcript

һݶ– 100,000 CFM Dust Collector Assembly

The Project
Foundry Application to Mitigate Dust Exposure
6 Months Before: Design and Engineering
4 Months Before: Fabrication
1 Week Before: 3-Person Crew Site Prep

The Crew
60 Years Crew Experience
Six-Person Installation Team

The Installation
Baghouse Assembly Built Up from Hopper
Custom Structural Steel and Staircase
Pre-Assembled Catwalk and Walk-In Plenum Access

Final Product
65-Foot Tall Assembly
90-Foot Tall Stack
1000+ Filters Installed
Meets EPA Standards

һݶ– Metal Fabrication • Industrial Ventilation

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Extend Baghouse Life With Dust Collector Maintenance /extend-baghouse-life-with-dust-collector-maintenance/ Tue, 24 May 2022 19:12:53 +0000 /?p=9693 So many signs can point to the need for dust collector maintenance. Your dust collector may run out of volume or pick up too much product. You may notice high differential pressure in your baghouse. You may even experience buildup in your ductwork. Doing regular industrial ventilation maintenance can increase bag life, improve your dust...

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So many signs can point to the need for dust collector maintenance. Your dust collector may run out of volume or pick up too much product. You may notice high differential pressure in your baghouse. You may even experience buildup in your ductwork.

Dust Collector Maintenance

Doing regular industrial ventilation maintenance can increase bag life, improve your dust collector’s effectiveness and extend the life of your ductwork. Maintaining dust collectors also lowers the amount of particulate emitted in your facility. Even if a baghouse is running well, preventive maintenance is crucial. Because the һݶteam understands the type and volume of material going through the system, our industrial ventilation maintenance programs are designed to help systems achieve peak performance.

The Most Common Dust Collector Maintenance Issues

When the һݶteam visits a facility to troubleshoot dust collection issues, some of the most common problems we see are:

  • Low air flow at the hoods
  • Broken ductwork or holes in the ductwork
  • Plugged ductwork
  • Premature bag wear or leaking bags
  • Leaking pulse valves

We often see that dust collection systems get a lot of attention when installed. Yet, a lack of staff resources or staff turnover can prevent systems from being properly maintained. We bring decades of experience in a wide range of industrial settings with us aswe service dust collectors and develop a preventative maintenance plan.

Industrial Ventilation Maintenance Checklist

The һݶteam conducts a maintenance review on every point in the system to ensure it’s operating at peak performance and meeting air quality standards. Our general checklist includes:

  • Differential Pressure Readings: These readings speak volumes about dust collection issues. If pressure is too high, bags are likely beyond their lifecycle or are handling too much capacity. If it is too low, that tells us the tube plate may be leaking.
  • Ductwork: We evaluate whether it was designed to effectively transport particulate as well as whether it has holes or significant wear and tear.
  • Fans: We check that fans are rotating at the proper rpm and that the number of amps the fan is drawing is not overloaded, which can lead to motor failure.
  • Air Quality Survey: A complete air quality survey that involves a complete testing and balancing checklist may also be included at the start of the process. If included, you will be provided with a detailed report of findings and a plan.

Many times, our engineering and maintenance teams collaborate based on your dust collector’s performance. By conducting an engineering survey—which reviews the entire system based on its design—we can dig deep into possible issues.

Why Choose һݶfor Dust Collector Maintenance

Because we design, fabricate and install dust collection systems, we have a complete understanding of how systems should be designed and can identify why systems may have issues. Our engineers, fabricators and field technicians are a well-integrated team with high standards for the systems we design and build.

Our multi-talented staff, located in Wisconsin, the Carolinas and Oklahoma, travel to locations throughout the United States for industrial ventilation maintenance. Experience less downtime and have problems resolved quickly with regular maintenance. Contact us today to learn more about scheduling a maintenance team visit to your facility.

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Dust Collector Maintenance [Video] /dust-collector-maintenance-video/ Fri, 12 Nov 2021 22:07:42 +0000 /?p=9465 IVI’s knowledge of dust collector systems goes beyond just design, fabrication and installation. We are also your partner for maintenance to maximize the performance of your dust collector. To learn more, press play below to view “Dust Collector Maintenance.” Transcript Common Dust Collector Maintenance Issues When we approach a plant, a lot of the most...

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IVI’s knowledge of dust collector systems goes beyond just design, fabrication and installation. We are also your partner for maintenance to maximize the performance of your dust collector. To learn more, press play below to view “Dust Collector Maintenance.”

Transcript

Common Dust Collector Maintenance Issues

When we approach a plant, a lot of the most common maintenance issues we see, and the easiest to find, are going to be the worn out duct work or low velocities, low volumes in the system. Holes in the ductwork can compromise the performance of the dust collection system.

What you’re going to look for is where those holes are, what the sources are, what the total volume on the system is, see if there’s blanking in any of the filters. Then, take it back to the collector and check to make sure that all the filters are working, not leaking through the tube sheet, and then take it back even as far as the fan or the exhaust. We want to keep everything running as designed and that the volumes are where they need to, otherwise it can just further compromise the ductwork.

Routine Maintenance Matters

The dust collection systems, a lot of times, are a project that’s put in, they get a lot of attention when they get put in, and then there may be turnover of staff, there may be a long period with no maintenance, so it’s not high on the radar. It’s just something that sometimes just goes by the wayside.

A Team With Vast Dust Collector Maintenance Knowledge

What sets һݶapart in our maintenance services is basically our knowledge of the systems. We do build our own dust collectors, we build a lot of our ductwork, we handle everything from the design, through the fabrication, through the installation, and then as well the maintenance.

Having a diverse staff, we have the ability to react quickly. Having our own fabrication shops in three different states also allows us to get anywhere in the U.S. within a fairly short turnaround.

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The Ingenuity and Engineering of Dust Collector Hood Design /the-ingenuity-and-engineering-of-dust-collector-hood-design/ Thu, 04 Mar 2021 18:46:49 +0000 /?p=9167 When it comes to industrial ventilation system design, the hood is the most crucial piece to ensuring the system functions effectively. Why? Because that is the critical point where particulates are captured and removed, leaving behind a cleaner, safer working environment. To ensure hoods fit a facility and its manufacturing process, dust collection hood design...

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When it comes to industrial ventilation system design, the hood is the most crucial piece to ensuring the system functions effectively. Why? Because that is the critical point where particulates are captured and removed, leaving behind a cleaner, safer working environment. To ensure hoods fit a facility and its manufacturing process, dust collection hood design takes a delicate balance of engineering and ingenuity.

Dust Collector Hood Types

Along with size and airflow rate, good hood design relies on the type of hood and where it’s located in relation to the manufacturing process. There are two primary types of dust collection hoods: enclosing hoods and capturing hoods.

Enclosing hood

An enclosing hood keeps the contaminant within the hood. These hoods completely or partially enclose a process so particulates cannot escape.

Capturing hood

A capturing hood is located next to the contaminant source. These hoods must be designed to draw and capture contaminant from outside the hood.

At IVI, we begin each design with the intent to use enclosing hoods, if possible, as they are better at helping to eliminate fine particulates, toxic contaminants and more. They also take less energy to do the job effectively.

һݶHood Fabrication

IVI’s Approach to Industrial Dust Collector Hood Design

Because hoods are so crucial to a dust collection system’s functionality, we treat each of our dust collection hood design projects as unique. In other words, we never copy hoods from project to project. Instead, we consider the combination of the contaminant—its density, size and toxicity—along with the manufacturing process. That’s where ingenuity and engineering come into play. The ingenuity is making sure the dust collection hoods fit within customers’ applications and needs. The engineering is using proven industry equations to determine volumetric flow rate.

We start many projects with computational fluid dynamics (CFD) modeling to visualize air flow patterns and determine capture velocities within the hoods and to measure pressure drops.

һݶTest Lab

In addition to CFD modeling, we also use our R&D test lab to simulate real-world applications. In the lab, we test either full-size or small-scale models to ensure they capture contaminants effectively before we fabricate and install full-size hoods.

Issues with Improper Dust Collector Hood Design

We’ve seen first-hand the effects of improper hood design. The most common hood design error we see in the industry is placing the hood too far away from the where the contaminant is generated. A hood’s primary purpose is removal of dust and other particulates from the process. When a hood doesn’t do that properly, issues multiply.

We’ve seen a specific instance of this in a tissue converting application where dust was settling on top of the hood rather than being pushed into the hood. This accumulating dust is hazardous for two reasons: It is a risk for fire and employees’ health and safety. In an industry where stringent production schedules rely on little downtime, maintenance crews had to stop production to clean the accumulated dust. It was a clear case of a dust collection hood not meeting design goals.

One Source for Dust Collector Hood Fabrication, Design

At IVI, we believe metal fabrication is as important as hood design. When building our hoods, we use abrasion-resistant or heavy-gauge materials to ensure they stand up to applications where particulates may cause wear and tear. In addition to ensuring we have smooth welds that won’t trap dust, we also use our fiber optic laser to accurately and precisely cut slots out of our hoods. Our laser cutter not only leaves the finished product looking aesthetically better, it also ensures a more accurate slot for better performance.

If you have noticed dust buildup in your facility, an improperly designed hood may be the cause. Contact us to see how our dust collection hood design experts can help make your facility and manufacturing process cleaner and safer.

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How to Tackle Dust Collector Bag Replacement /how-to-tackle-dust-collector-bag-replacement/ Thu, 16 Nov 2017 19:06:42 +0000 /?p=6495 Changing dust collector bags is one of the least desirable jobs of industry maintenance. Crawling into the collector is not only dirty business, it also requires you to take caution against exposure to the dust—sometimes harmful dust—that’s been collected in the baghouse. But, to keep your facility clean, healthy and comply with air quality regulations,...

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Changing dust collector bags is one of the least desirable jobs of industry maintenance. Crawling into the collector is not only dirty business, it also requires you to take caution against exposure to the dust—sometimes harmful dust—that’s been collected in the baghouse. But, to keep your facility clean, healthy and comply with air quality regulations, dust collector bag replacement is a must when the need arises.

When to replace baghouse filters

For the most part, there are only three reasons to change baghouse filters:

  • When they can no longer be cleaned because dust has accumulated to the point of plugging the fabric’s air passages, keeping the vacuum from pulling in unwanted dust.
  • When the bags have developed holes.
  • When the regulates your company or industry to change bags.

While some facilities change bags once per year because their dust collectors capture large quantities of especially fine, hazardous dust, most of IVI’s customers can go two to 10 years before having to schedule dust collector bag replacement.

Facilities that change bags more than once a year may be doing so because of a unique situation—the collector is capturing an especially tough material, like a wet, corrosive or abrasive dust. Facilities that change bags often but are not in this situation likely have a dust collector that doesn’t correctly match their manufacturing process.

Checking your industrial dust collection system

If you’ve just installed a new industrial dust collection system, it’s best practice to check the system regularly to ensure it’s running efficiently and the bags have been installed correctly.

Here’s how to tell whether dust collector issues may be related to the bags:

  • High differential pressure: Bags that haven’t been installed correctly, or are retaining excess amounts of dust, will lead to high differential pressure within the baghouse. As it becomes more difficult to pull air through the bags, the difference in the pressure before air enters the bags and after exiting the bags increases.
  • Baghouse dusting: Dusting is noted by a visible emissions plume coming out of the stack or by dust in the clean air section of the collector. Bags that are the wrong size or fabric for the particulate may not be installed correctly, may not be sealed or have holes that are contributing to the dusting.

Replacing baghouse filters

Dust collector bag replacement: A quick tutorial

Before removing filters:

  • Obtain and follow a Confined Space permit, if required.
  • Manually pulse down existing filters.
  • Allow the screw auger and rotary air lock to remove waste.
  • Conduct proper lockout-tagout per or requirements.
  • Ensure employees are trained on hazards associated with the task and are wearing the proper personal protective equipment.

Removing old filters (pertains to top-load bags only):

  • Open clean air section doors and remove pulse tubes and cages. (Note: IVI’s baghouses do not use hold-down hardware, but if your baghouse does, remove this hardware before proceeding.)
  • Flex the bag’s seal toward the center of the tube sheet hole and drop the bags into the dirty air section.
  • Remove all the old bags that were dropped by accessing the hopper. Count the bags to verify you have removed them all to avoid damage to your dust collector.
  • Dispose of dirty bags in a dust-tight bag or sealable waste container.
  • Close and bolt or screw shut access doors.

Installing new filters:

  • Vacuum the clean air section to remove accumulated dust and debris.
  • Drop new filters—one at a time—through the tube sheet.
  • When the filter is unfolded into the dirty air section, flex the snap band toward the center of the tube sheet hole. Do not bend the snap band at the seam.
  • Place the filter snap bands on either side of the tube sheet, and push the band toward the perimeter of the tube sheet hole. You’ll hear the snap when it’s properly sealed.
  • Slowly drop the cage down the center of the filter until the venture sits snug on the filter. Gently step down on the venture to seat the cage. If you have hold-down hardware, reinstall it.
  • When all bags have been replaced, reinstall all pulse tubes.
  • Inspect all the bags for uniformity.

We also recommend testing your system using a fluorescent powder. Starting your industrial ventilation system using this powder will allow you to see whether it is making its way through to the clean side of the bag. If it is, the bag has not been installed properly.

When, and if, you need to replace bags, we also recommend taking the following steps to prevent maintenance and reduce production downtime:

  • Keep a bag location replacement chart.
  • If you have consistent bag failures, retain a typical bag for inspection.
  • Retain bags with unusual or non-characteristic failures.
  • Maintain an adequate supply of replacement bags.

By maintaining and changing your baghouse filters when needed, your dust collector will run more efficiently at a lower cost.

Contact һݶfor assistance

Unfortunately, many things can go wrong during a dust collector bag replacement procedure. Improperly seated bags can lead to poor dust collection, which can lead to failing government regulation tests and to excessive dust in your facility, which can adversely affect product quality.

If you are unsure about changing your own baghouse filters, contact us. We will not only change dust collector filters, we also can help analyze your system to help extend bag life, thereby reducing how often you’ll need to do one of the dirtiest maintenance jobs in industrial ventilation.

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Types of Industrial Baghouse Dust Collectors /industrial-baghouse-dust-collector-types-and-how-they-work/ Thu, 06 Apr 2017 14:56:44 +0000 /?p=6228 What is an industrial baghouse dust collector? An industrial baghouse dust collector, when coupled with an industrial blower, pulls in airborne dirt, and other particulate matter generated by manufacturing processes. The baghouse dust collector then cleans the air by filtering out floating dust and dirt. Once clean and free of contaminants, the dust collector allows...

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What is an industrial baghouse dust collector?

An industrial baghouse dust collector, when coupled with an industrial blower, pulls in airborne dirt, and other particulate matter generated by manufacturing processes.

The baghouse dust collector then cleans the air by filtering out floating dust and dirt. Once clean and free of contaminants, the dust collector allows the air to move through the baghouse and be released either back into the manufacturing space or into the atmosphere.

baghouse graphic

Types of industrial baghouse dust collectors:

After learning about your facility, regulatory requirements and particulate matter you need to filter, the һݶteam taps decades of experience to identify the industrial baghouse dust collector that’s right for you. Here are the types of baghouses we consider:

Pulse Jet Baghouse Dust Collector

In pulse jet baghouse dust collector operation, puffs of pressurized air “pulse” incoming air through the filters for cleaning. Pulse jet dust collectors are the most common type of baghouse dust collector used in industry today.

Reverse Air Baghouse Dust Collector

Industrial reverse air baghouse dust collectors are typically used in wood dust applications with larger chips or when particulate matter has low densities and/or large aspect ratios. Reverse air baghouse operation involves a low-pressure reversed flow to backflush the air through the filter bags. Once backflushed, the filtered air is released back into the environment for recirculation.

Shaker Baghouse Dust Collector

Industrial shaker dust collectors are occasionally used for areas and facilities where it’s not practical to have compressed air. Mechanical shaker baghouses remove particles by mechanically shaking the filter bags. This causes the heaviest pieces to fall into a hopper while the smaller pieces are stuck against the inside or outside of the bags, depending on the design.

Shaker baghouse dust collectors are nearly obsolete and have limited applications due to required regulatory efficiencies and necessary maintenance.

Custom Design Baghouse Dust Collector Capabilities

Whether your facility requires a reverse air or pulse jet baghouse dust collector, һݶhas a custom design-build department which allows us to conduct both engineering and custom design in-house for any type of industrial baghouse dust collector. We can design a unique baghouse to fit your needs according to regulatory emission rates, particle type, explosion protection guidelines, the size and type of your facility and air-to-cloth ratios.

Put a Custom Baghouse Dust Collector to Work for You

Understanding what an industrial baghouse dust collector is and how it works is the first step. If you’re ready for an industrial baghouse design that caters to your facility’s requirements, complete the form below.

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