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EFFICIENT, TIME-SAVING DELTAMAXX FILTERS FOR LEAN MANUFACTURING

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EFFICIENT, TIME-SAVING DELTAMAXX FILTERS FOR LEAN MANUFACTURING

Lean Manufacturing is about simplifying and improving processes, solving problems, and reducing waste of time and materials. DeltaMAXX filters can help you achieve all these lean goals… for your dust collection system, at least. Here are some ways our filters can help get your dust collector as lean as the rest of your workplace (or leaner):

  • EFFICIENCY – with nanofiber material that is 95% efficient capturing particles as small as 0.3 microns, DeltaMAXX filters keep your air clean and control fine dust better than cheaper materials
  • LONGER-LASTING – with DeltaMAXX you can expect up to twice the filter lifespan. If you’re looking for filters for lean manufacturing, longer lifespan saves money on filter purchases and saves time on several process steps, from ordering to changeouts.
  • LESS WASTE – because nanofiber material is surface-loading instead of depth-loading, dust collects on the outside of the filter, not stuck in the material. Filters pulse cleaner and need pulsed less often, preventing waste of compressed air.
  • RELIABILITY – when you’re buying filters for lean manufacturing, it’s important to know that you will always get consistent quality so there’s no wasted time dealing with filter problems or replacing them too often.
  • TIME-SAVING SERVICE – DeltaMAXX filters come with the customer support only Imperial Systems offers. You’ll work with the same aftermarket team member every time, so they’ll know what you need and make the order process smooth and fast.
  • FIELD SUPPORT – Sometimes keeping your process lean means knowing who to call to solve a problem quickly and efficiently. Our ServiceMAXX team has the experience to troubleshoot and fix a problem fast. No wasted time trying to figure out what’s wrong, and no wasted production having your employees away from their work trying to fix it.

DeltaMAXX Dust Filter Brand

If you’re going lean, every part of your process needs to become more efficient, reduce waste, and improve quality. For these reasons, DeltaMAXX filters for lean manufacturing are one way to move toward those goals. A dust collector problem can shut down a machine or an entire process, and that’s a huge waste. Using high-quality filters helps make sure this doesn’t happen.

 

 

Imperial Systems Quarterly Newsletter | Issue II

The Second Issue of Dusty Jobs Newsletter. Articles include How to Troubleshoot a defective filter and a story about the different people at Trade Shows and how they score free gear.

Dusty Jobs Newsletter Issue 2-1

 

Download DUSTY JOBS | Issue 2 PDF

 

DUST COLLECTION DISASTERS: LEAKING FILTERS

Your dust collector is supposed to keep dust or fumes from getting back into your facility. That means that the last thing you want to see is what we found when our ServiceMAXX technicians went on a service call to this facility: badly leaking filters in their horizontal dust collector.

How do you know you have leaking filters? Obviously, you might see dust in places it shouldn’t be, like coming out clean air vents. You might also see dust in the clean air plenum of the collector, but this isn’t exactly a place that’s easy to get to, especially in a horizontal collector.

The best way to find out if you have dust getting through a leaking filter is to have a professional conduct a dye test. Not only will this show you whether there are holes in your filters, but it will also show you any other places that dust is getting where it shouldn’t be.

 

DYE TESTING

In a dye test, a dye that fluoresces under ultraviolet light is run through the collector just like regular dust. After this has been allowed to go through the collector, everything is inspected with the UV light.

If there are no problems, the dye should only appear on the outside of the filter: the side that is supposed to be in contact with dust.

When spots on the inside of the filter start to light up, you have a problem. Dust isn’t supposed to be on the clean air side of a filter, and if the dye is getting through, dust is too.

 

WHAT WE FOUND

When our service technician visited this company, he found filters that looked like this:

Leaking Filters Dust Collector Filter

Leaking Filters around the edge of dust Collector

The blue marks show where the dye accumulated after running through the system. This allowed the service technician to discover the locations of several problems. Some of the filters had holes in the filter media, which was probably caused by large particles hitting the filters and damaging them.

Some of them also appeared to be leaking around the gaskets. This is a common problem in horizontal collectors because of the yokes that support the filters, which are easily bent. This can pull the filter away from the tube sheet or the door and cause leaking filters.

Leaking Filters Leaking around the gasket in the Dust Collector

This photo shows how much dust was sitting on the yokes. These are inside the filters and should never have any dust on them unless you have leaking filters.

Dust Collector Filter Yoke

Our technician then took a look inside the clean air plenum to see how much dust had been getting past the filters. The results weren’t good:

This valve in the clean air plenum should have no dust on it or in it. The dye test showed a large amount of dust accumulating inside the clean air plenum. This dust can be very difficult to clean out, even after leaking filters have been replaced. If there is dust in the clean air side of the collector, it will continue to get into your clean air stream even after the filter issue is fixed.

 

REASONS FOR A DYE TEST

Any system can benefit from inspection by a trained technician. This can find problems you didn’t know were there, or things that can be fixed to prevent a problem.

Some problems that may be identified by a dye test:

  • Defective filters with manufacturing flaws
  • Failure of gasket seals
  • Damage to filters due to large particles hitting them (or being handled incorrectly)
  • Filter material damaged by high differential pressure
  • A bent or warped tube sheet (usually a problem in horizontal collectors)
  • Other areas where dust is getting through
  • Dust in the clean air plenum from past leaks that needs to be cleaned up

 

One frequent cause of filter failure is using the wrong filter media for your dust. DeltaMAXX nanofiber filters are highly recommended over cheaper and less efficient material, and for special applications media like spunbond PTFE can be used. The wrong filter media can cause filters to fail very quickly.

DeltaMAXX Filters

As another good reason to have a technician pay a ServiceMAXX visit to your facility, the inspection and dye test results can be presented in a report to prove that your facility is in compliance and everything is up to standards.