Dust collectors are essential for any industrial manufacturing environment. This machine filters harmful contaminants from the air, collects dust for disposal, and returns clean air to the facility, mitigating health risks from dust exposure. Studies have shown these health risks include respiratory diseases such as chronic obstructive pulmonary disease (COPD), as well as pneumoconiosis or cardiovascular problems like ischemic heart disease. 

To be effective, however, facilities need to have appropriately sized dust collectors. An undersized unit can allow particulates to escape, risking worker health, clogging factory equipment, increasing maintenance costs, and hindering efficient production. The team at Mideco uncovers the indicators that your facility might have an undersized dust collector, and why it’s so important to keep its maintenance close at hand!

Dust Backing Up in the Collector Hopper

One of the most visible signs of an undersized dust collector is dust backing up into the hopper. This section is intended only for temporary debris storage, and accumulation can lead to serious hazards including machine damage or risk of fire. Regular inspections and timely emptying of the hopper are crucial to avoid these risks. 

Short Filter Life or Filter Failure

Filter life is influenced by several factors – including the type of dust collected, hours of the dust collector operation, and the effectiveness of the pulse cleaning system, just to name a few. Generally, filters can last up to a year, though in extreme cases, they need replacement every three to six months. Premature filter failure often indicates the system is handling more dust than it is designed for.

High Differential Pressure (DP) Gauge Readings

Differential pressure gauge readings are excellent indicators of filter health. New ones typically show DP readings of one to two inches – as filters load with dust, resistance and readings increase. A reading above five inches signals the need for filter replacement. 

Persistent high DP readings that don’t drop during pulse cleaning cycles suggest the dust collector might be too small. However, other factors, such as a clogged vacuum line, can also result in high DP readings, making a thorough system check essential.

Air-to-Cloth Ratio

A lower air-to-cloth ratio is ideal for dust collectors as it provides more filter media area for the selected air volume, leading to lower dust loading, lower DP, and longer filter life. Undersized collectors often operate with a higher air-to-cloth ratio due to insufficient filter media area, resulting in heavier dust loading and clogging, ultimately diminishing system performance. This also necessitates more frequent filter changeouts, increasing replacement costs and system downtime.

Air Flow Loss

Excessive dust on the filters can weaken the system’s airflow, especially at the suction or the hoods. This hinders the machine’s ability to move all the dust it collects, causing buildup within different system parts.

Upgrade your dust collector with Mideco!

Installing an appropriately sized dust collector is crucial for maintaining high performance and compliance with industry standards. An ill-fitting system can lead to increased energy and maintenance costs and reduced efficiency.

At Mideco, we offer advanced industrial dust collection tailored to various industries. Ensure your facility meets industry and health standards with our state-of-the-art solutions. Contact us today to upgrade your system, and maintain worker safety.