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 ��һ��ݶ�custom 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 ��һ��ݶ�team 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 ��һ��ݶ�team is ready to design and engineer, fabricate and install a new long-lasting industrial baghouse solution for you.

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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��һ��ݶ�Engineers 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 ��һ��ݶ�or not, ��һ��ݶ�can assist in these leak detection tests and help diagnose problems and come up with long-term solutions.

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The ��һ��ݶ�Process for Planning Manufacturing Ventilation Systems

Because every facility is unique, the process of manufacturing industrial ventilation systems begins long before a single sheet of metal is cut.

1. First, an engineering team will evaluate the facility and recommend proper system design. At IVI, our team will engineer a solution which improves the manufacturing environment, removes particulate matter from the air, meets emission standards, withstands site-specific wear and tear and is easily maintained by site personnel.
2. IVI’s design team will take this solution and fit it in your facility to be as minimally invasive as possible. IVI’s use of modeling software ensures there are no surprises during the installation phase, and that any logistics for integration into your facility have been worked out.
3. Fabrication follows. In this phase, our in-house sheet metal workers construct high-quality, long-lasting components for your system. The team brings deep experience fabricating custom metal solutions to each project. The result: Accurate fabrication that supports on-time installation and commissioning.
4. After your system components have been fabricated, IVI’s team of talented installers will place the system into your facility. At IVI, we understand the value of your process. We’ll work with your facility to ensure there is minimal interruption to your operations and production.
5. Once installation has been completed, IVI’s team will ensure your system is properly commissioned, tested and balanced. During commissioning, ��һ��ݶ�will thoroughly inspect all system components for proper operation. Testing and balancing will tailor the system to your process, ensuring proper collection, transport velocities and performance.
6. Once installation and commission are complete, all that remains is to train your personnel to maintain and operate the system. IVI’s team will make sure you have the skills, knowledge and tools to keep your system operational for a long time!

IVI’s Role as an Industrial Ventilation System Manufacturer

When planning an industrial ventilation project, the ��һ��ݶ�design, engineering and fabrication team takes the following factors into account:

Facility Evaluation

��һ��ݶ�engineers conduct on-site evaluations to determine the ideal design for each industrial ventilation system they fabricate. While evaluating the facility, our team measures existing infrastructure to ensure the seamless integration of a new ventilation system.

Production Process Review

Next, the ��һ��ݶ�team will review the production process. This helps us evaluate the most effective placement for hoods and ducts to capture and remove particulate matter or fumes. We also ensure appropriate materials, sizes and durability for an effective process.

Contaminants Identification

Particulate matter varies per industry, from abrasive dust to noxious fumes and anything in between. The type of contaminant determines which material should be used for duct fabrication. Silica, for example, requires ducts designed to withstand the wear and tear of an abrasive particulate matter. Industrial ventilation system manufacturers can fabricate durable ducts with the most suitable material type for a lasting solution.

Regulatory Requirements Gathering

Based on the industry and application, stringent local, state and federal standards and regulations must be met such as (OSHA), (MSHA), (EPA), (NFPA) and local environmental authorities. IVI’s design, engineering, manufacturing and installation processes are designed to help facilities managers meet these requirements.

Evaluating Off-the-Shelf vs. Custom Industrial Ventilation System Design

Off the Shelf

Some companies purchase a premade dust collector and then build a system around that. However, a one-size-fits-all approach may not be a good fit for your space and goals. When the unit is not designed with the rest of system in mind, problems can arise including:

• Difficult maintenance
• Particulate matter accumulation
• Expenses for rework or replacement
• Ineffective collection
• Waste handling issues
• Overuse of valuable production footprint

When evaluating a new industrial ventilation system, a turnkey solutions provider like ��һ��ݶ�can help evaluate whether these risks or others will affect your project.

Custom Design

A custom design begins with the end goal in mind for an efficient, lasting solution. It starts with a thorough site assessment and takes all factors into account including the industry, process, application, contaminant and facility size and layout. When you opt for a customized design, guesswork and assumptions are eliminated as accuracy and efficiency are maximized.

Additionally, working with a single team allows for easy back and forth communication throughout the entire process and offers continual support. It creates an opportunity to evaluate system design before installation using 3D system design and . This leads to fewer costly mistakes, better air quality and energy efficiency. Plus, there are no unpleasant surprises during installation.

��һ��ݶ�is a Full-Service Industrial Ventilation System Manufacturer

As an industrial ventilation system manufacturer, IVI’s experienced design, engineering, in-house metal fabrication and installers ensure a system that removes dust, streamlines maintenance and meets regulatory requirements.

Connect with us to discover how a custom industrial ventilation system checks all the boxes. Get a quote today by completing the form below.

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published regulatory change for mining facilities’ air quality related to respirable crystalline silica in April 2024, with changes taking effect June 17, 2024. Here, we’ll answer your most pressing questions to help you meet the MSHA respirable crystalline silica standard in your facility.

Navigate the proposed respirable crystalline silica standard with a proven partner. Talk with an ��һ��ݶ�project engineer today. It’s the first step you can take toward meeting the proposed MSHA Respirable Crystalline Silica Standard.

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Project managers often make this mistake when searching for an industrial ventilation fabrication company.

Many project managers find themselves in a predicament after hiring the lowest bidder over the most detailed. They may need another metal fabrication contractor to come in after the first and do it correctly, effectively doubling or tripling their budget.

This guide helps you avoid the all-too-common pitfalls.

Tip #1: Ask about history and metal fabrication experience

There is no way around it: To become a skilled metal fabricator; one needs years of experience.

A competent custom industrial ventilation fabrication company will have a dense portfolio of projects, a long history of being in business and an experienced team. When you put in an inquiry, this should be one of the first questions you ask.

Tip #2: For custom metal fabrication, solicit a transparent, detailed project scope

Too often, when project managers sign with a company that offers the lowest bid, they later find the contractor was not detailed enough in their scope of work. That often results in a flurry of change orders or project rework. One way to avoid this mistake is by asking for a bid sample up front. This will allow you to see the detail at which a project is scoped and to provide feedback in advance of the bid being sent.

Tip #3: Ask if the company offers more than metal fabrication services

Engineering and design are typically handled by separate organizations. When different organizations handle various parts of the same project, disconnects in communication, process and progress can result.

IVI, on the other hand, is a full-service industrial ventilation design, engineering, manufacturing and installation company. That means the ��һ��ݶ�team oversees both engineering and design of your industrial ventilation system. This cuts the lags between handoffs lowering the risk of miscommunication. The result: Projects are more efficient and effective.

Ask the question up front, “Is your team capable of managing this project from start to finish? If not, what aspects are you willing to cover and how do you manage the transitions?”

Tip #4: Confirm metal fabrication equipment upgrade schedules

Any custom industrial ventilation fabrication company will be regularly updating and upgrading equipment for two reasons:

• Poorly updated equipment creates subpar products
• Equipment failures cause delays in project progress

Be sure and ask any prospective industrial ventilation manufacturer about current equipment, planned upgrades and if they have contingencies in place to mitigate equipment failure.

Tip #5: Find out how and when their project managers will be communicating with you

Last but not least, set clear expectations around how and when you will hear from your project manager. At what points in the project will they be communicating with you? How and when will delays or scope changes be addressed? Creating clear guidelines for communications up front sets you and your new project manager up for a successful professional relationship.

Bonus tip: safety plan

Does your prospective industrial ventilation fabrication company have a safety plan in place? Because safety incidents on a jobsite can affect your productivity, it’s critical to ask about safety training, safety plans and safety record.

Industrial ventilation company selection

Gathering the information outlined above can help you ensure the industrial ventilation company you select is the partner you want.

��һ��ݶ�has proudly been in the metal fabrication business for over 30 years, uses the most up-to-date equipment, and offers start-to-finish industrial ventilation design, engineering, custom metal fabrication and installation services on all of our custom projects.

Are you looking for an industrial ventilation fabrication company that can bring your idea to life? Get a quote today.

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Thank you for considering IVI, Inc. for your ventilation project. Whether you need a full ventilation system engineered from the ground up or have a maintenance need, your goal can be accomplished with the right solution at a competitive cost.

This guide covers the details required to:

• Assess your needs
• Define goals
• Establish timelines
• Identify resources
• Address challenges
• Determine costs
• Specify deliverables and exclusions

IVI’s experienced team is here to help you along the way, and we look forward to serving you from start to finish.

The Value of Proficient Planning

A detailed project scope sets you up for a smooth, successful ventilation project.

This initial phase of gathering critical information reduces your risk and helps provide the best outcome. With sufficient planning and complete information, you’ll avoid surprise costs and unexpected downtime. The scope can also be referred to throughout the project to keep contractors on task.

Why Does This Matter to You?

Imagine that a customer receives four quotes with a vast pricing range for an industrial ventilation system. They select the least expensive option, but don’t realize why the quote is so much cheaper. Because important details about their unique building layout are missing from the scope, they soon find out that the lower-cost “one-size-fits-all” system doesn’t fit. Frustrations build as additional quotes and change orders are needed to address the issues, the project gets behind schedule and ends up over budget.

Now picture a customer who needs a dust collector. Their project goals and deliverables aren’t clearly stated when they initiate the project. Trouble soon arises when the customer realizes their moist contaminant with heavy loading, which they didn’t mention in the scope, plugs the undersized cartridge collector they received. Due to the reduced system performance, targets aren’t met, resulting in costly fines and health risks to the employees. The relationship with the vendor becomes strained, time is consumed and costs rise as they work to correct the issue.

Having a well-developed scope can help avoid these types of costly and time-consuming issues.

The Basics

The information you initially provide helps build the foundation for an accurate quote, the best solution and maximum cost savings. Your industry, goals and other details will be considered to develop a thorough understanding of your project, which allows your needs to be met. Let’s begin with an overview of your business and industry.

Preferred Contacts

• Who is the main point of contact for this project scope?
• What is your preferred method of contact? Phone / Email / Text / Video Conferencing
• Who else needs to be involved? e.g., EH&S, operations, engineering, project management, etc.

Work Site Details

• Where is the location of the work site?
• Will local labor be utilized?

Industry Details

• What is your industry?
• Which materials are involved?
• What special requirements come with your industry? (e.g., duct work material type, restrictions on finish and joint quality, high wear)

Define Your Goal

• What do you need to accomplish?

Project Scope Guide

Past and Present Challenges

Past challenges help provide a full picture of today’s project needs.

• What issues have you dealt with in the past?
• How have past issues been solved?
• How long has the issue been a problem?
• What is the current need?
• What issues do you foresee with your upcoming project or maintenance?
• What are the special requirements for your project?

Establishing a Timeline

It’s important to stay on track with minimal interruptions to your operations. By documenting your needs, a thorough plan will be devised to reduce downtime and keep you on schedule.

• What shifts do you operate?
• Do you have existing planned downtime for maintenance?
• Can installation take place during all shifts without interruption to production?
• When is your desired completion date?
• Is there flexibility with your desired completion date?

Existing Equipment Information

If your project involves existing equipment, a ventilation solution will be developed for the best fit and results.

• Provide existing equipment manufacturer data if possible.
• Provide equipment serial numbers if possible.
• Provide pictures if possible.
• Provide any known issues with current equipment or changes that have been made since original installation date.

Space Constraints

Spacing plays an important role in determining the right ventilation solution.

• What space constraints exist at your facility?
• Provide measurements if possible, using Imperial measurements.
• Provide pictures if possible.

Surface Preparation and Paint

The proper surface treatments will be determined for your industry. What are your surface preparation requirements?

• Galvanized
• Passivation
• Paint
• Other

On-Site Visit

Observing your production process in person allows a comprehensive and accurate assessment of your ventilation.

• Ideally, it’s best to assess your production and ventilation operations in action. Is this possible? Or must production be shut down?
• If possible, have operators, a foreman and the project contact on-site for the assessment.
• Air readings will be taken, and space constraints will be measured.
• Your processes will be observed, and you may receive recommendations to improve efficiency.
• The best solution will be determined for long-term results.
• Site constraints, unknown to the customer, may be identified with IVI’s experienced teams extensive installation expertise.

What’s Next

Once you submit your project scope, your needs will be evaluated and additional questions may follow as needed. You’ll receive recommendations and a competitive quote to meet our ventilation needs.

Thank you for the opportunity to earn your business.

What Sets ��һ��ݶ�Apart

Dedicated from Start to Finish

��һ��ݶ�designs, builds and installs custom dust collection systems and maintains other dust collection systems, ductwork and industrial HVAC systems around the country. ��һ��ݶ�not only works on the engineering piece of your project, but also performs fabrication and installation as a dedicated partner from start to finish. This ensures a cohesive solution with a full perspective of the ventilation design and operations.

��һ��ݶ�has a rigorous safety program and follows protocols for each individual industry. Many ��һ��ݶ�staff members in the field are trained in cranes, rigging, a multitude of lifts and material moving equipment. IVI’s extensive experience and vast number of nationwide collection systems ensures the knowledge and resources to get the job done right.

IVI’s mission is to get the job done safely and efficiently—ultimately resulting in a successful and more cost-effective project for you.

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What to Expect from an Industrial Indoor Air Quality Survey [VIDEO]

Transcript

After ��һ��ݶ�gets on site, we take a lot of different air readings and evaluate the the dust collection unit itself for wear and tear, the fan. So when we get back to the office we put together a pretty nice report basically laying out everything that we’ve seen on site. You know, giving you back all the data on your equipment so if your dust collection system has 20 points we basically give you a nice chart back that shows each point, what it goes to, the volume that it has, the static pressure at each point. Some indication on whether or not it’s doing its job and picking up the the particulate. So we give you all the basic information of what you have.

And then once we get through that we give you a section of recommendations pointing out all the improvements that could be made or we’re just generally stating that what you have is good, the design is acceptable and the volume is adequate what those are, we’ll actually go back through and say okay, these were the recommendations for this dust collector. We’ll put together an actual proposal on the cost to do that.

Being that we are a turnkey company we’ll put together a conceptual design, a price for it and then upon acceptance we would give you a final design deliverable along with an implemented solution.

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Transcript

��һ��ݶ�Engineers Share the Keys to Proper Industrial Ventilation Hood Design

Hood design is very important and actually crucial for the functionality of a collection system. Improper hood design can cause a lot of issues and probably the most common one is the placement of the hood in relation to where the contaminant is being generated. A lot of times the hoods are too far away from the contaminant generation point to be effective.

Industrial Ventilation Hood Design: What Sets ��һ��ݶ�Apart?

��һ��ݶ�takes the design of hoods very seriously. One of the things that sets us apart the most I believe is just our experience. And two things that we do to ensure that hoods are going to function properly when they’re installed are to first look at them through Computational Fluid Dynamic Modeling to see where air is going within the hoods. And the other thing that we do is we have built a test lab for trying out some of these hoods to ensure that they’re properly collecting the contaminant that we’re trying to capture.

The Science and Art of Hood Design

Hoods are kind of a unique balance of science and art. We use a lot of equations from industry publications on sizing and determining volumetric flow rate for our hoods. But there’s also an art to ensuring that these hoods fit within the applications and the needs of our customers.

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Transcript

Reasons For Engineering Studies

There’s a couple reasons why customers should contact us to do these evaluations and what the benefit from those are. After time goes on they realize or they notice that some areas of then plant just seem more dusty or there’s more smoke than there used to be. That could be that there was a process change. Or secondly, they call us in and we look at the ventilation and we might get into the system doing the evaluation and come to find out that a blast gate or an orifice plate was changed. And the volume that they think that they have at current equipment really isn’t true.

The Engineering Study Process

Each branch has to be balanced at the beginning of the system startup and that plays a role at the volume and the static pressure. So as soon as you touch one piece of this entire network, it directly affects every branch. When you’re changing the volume going to a certain piece of equipment, you could see a lot of dropout in your ductwork. And over time, that material drops out and fills up in your ductwork. You’re adding a lot of weight to a suspended piece of ducting that may or may not have had a hanger properly designed to support that weight.

Engineering Studies Ensure Optimal Operation

For us to get in there and see exactly what’s going on with the system and make sure that everything’s clean and clear, each branch has good volume, the fan is operating at a good point in the curve. It all kind of ties together just to make sure that it’s operating the way it should be.

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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 ��һ��ݶ�team 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 ��һ��ݶ�team 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 ��һ��ݶ�team 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 ��һ��ݶ�for 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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