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Dust and Fume Collection: Do you need it?

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Dust and Fume Collection: Do you need it?

DUST AND FUME COLLECTION:  SOME INDUSTRIES THAT MIGHT NOT KNOW THEY NEED IT

Dust and fume collection in a manufacturing facility is important for many reasons.  Here are the top five reasons you should consider:

 

Top 5 reasons you need dust and fume collection

NOT CONVINCED YET?

Can you name the metal that causes cancer, damages skin, eyes, lungs, and kidneys, and is found in everything from stainless steel to dyes and pigments?

 

If you said this compound is HEXAVALENT CHROMIUM (https://www.osha.gov/SLTC/hexavalentchromium/) you’re right.

 

Chromium is a component of stainless steel, added to make the steel more corrosion-resistant. The fumes produced from welding, laser cutting, or plasma cutting stainless steel contain hexavalent chromium. While this form of chromium is known to cause cancer, it also directly attacks the lungs and kidneys and can cause severe eye and skin irritation.

Hexavalent chromium doesn’t just appear in welded or heated stainless steel. Electroplating with chrome also presents a hazard, and hexavalent chromium compounds are used as pigments in inks, paints, and many types of plastic. Working on any material plated with chrome or coated with a chromium-containing material may release hexavalent chromium into the air.

Think hexavalent chromium isn’t something to worry about in your type of business? You may need to reconsider. OSHA TESTING (OSHA TESTING: https://www.osha.gov/SLTC/hexavalentchromium/) showed which types of facilities had detectable levels of this dangerous metal in their air. The following are some of the top offenders:

  • Nonresidential building
  • Highway, street, and bridge
  • Foundation and structural materials
  • Foundries
  • Forging and stamping
  • Architectural and structural metals
  • Boiler, tank, and container
  • Coating
  • Engraving
  • Heat-treating
  • Agricultural machinery
  • Mining machinery
  • Ventilation and air-conditioning
  • Aerospace products and parts
  • Ship and boat building
  • Automotive repair and maintenance

Any surprises on this list? If your facility is part of any of these industries, contact us at 800-918-3013 for an assessment of your dust and fume collection needs.

 

Understanding Cold Spraying and Its Impact on Your Metalworking Facility

Within the metalworking industry, the demands for diverse material coatings are on the rise, and the development of application processes that address environmental concerns is an ever growing field. Thermal spraying provides an attractive coating technique because it offers a wide selection of materials that have a reduced environmental impact as compared to conventional methods. Imperial Systems meets today’s top market needs by offering solutions that address problems from plasma, flame wire, flame powder, warm spraying, and cold spraying. We commit to helping you better prepare and protect your facility as your processes evolve and expand.

High-Velocity-Oxy-Fuel-Spraying

There are advantages to thermal spray coating techniques because they tackle the many problems of wear, corrosion and thermal degradation by engineering surfaces with customized coatings. Thermal spraying offers greater thickness capacity than traditional surface modification processes with minimal hazardous waste and no size restriction for parts.

High velocity oxy-fuel (HVOF) spraying is a thermal spray system based on the combustion of gases or a liquid fuel. The resulting high velocity propels the coating particles at near supersonic speeds before impact onto the surface, which generates high coating quality. One of the key benefits of this system’s high velocity is the extremely high coating density and low oxide content.

Cold spraying is an emerging form of High Velocity Oxygen Fuel (HVOF) technology intended as a greener alternative that will satisfy increasingly rigorous environmental and health safety regulations. A number of materials have already proven to be suitable for cold spray including decorative, biomedical, automotive, industrial, and space exploration materials. The cold spraying process has huge potential of growth with more applications in new areas developing constantly.

Cold spraying need not be a dangerous process if the equipment is treated with care, and if correct spraying practices are followed. Ideally, equipment should operate automatically in enclosures specially engineered to extract fumes, reduce noise levels, and prevent direct contact with the spraying head. In addition, OSHA recommends that every metalworking facility be fitted with the appropriate dust and fume extraction system to reduce the risks associated with such processes, such as exposure to air pollutants and combustion susceptibility.

The Imperial Systems CMAXXTM Dust Collector System is specially designed with PD technology that allows for maximum Indoor Environmental Quality (IEQ) in your facility. Some of its features and benefits include:

  • Increased cleaning power and energy efficiency with high-performance manifold mounted pulse valves.
  • 10% More filter media than other same-sized vertical cartridge collectors.
  • Vertical cartridge design for a longer filter life.
  • 100% Total pulse distribution.
  • Best in class internal velocities.
  • 15 Year manufacturer warranty

At Imperial Systems, we know the hazards that metalworkers face each day, and we continue to reach above and beyond the safety standards set by OSHA and the NFPA. If you’re looking for equipment that offers real solutions, delivers the cleanest air and provides you with the greatest cost savings, then contact Imperial Systems today at 800-918-3013. We’ll match your facility with dust collectors and filters that will improve your facility’s readiness for cold spraying, and any other new metalworking technology developments that may come along!

Minimize The Risk of Thermal Spraying

The metalworking industry is compromised many different aspects of metal fabrication encompassing welding, thermal spraying, sanding and shot blasting, and plasma cutting. Thermal spraying is is used for repairing damaged surfaces, temperature/oxidation protection, corrosion protection, crankshaft reconditioning and conditioning, and altering thermal conductivity. The process of thermal spraying  comes in many applications from cold spraying, plasma spraying, wide arc spraying, high velocity oxygen fuel spraying, and warm spraying. While there may be variations in the applications of thermal spraying they all have similar risks.

High-Velocity-Oxy-Fuel-SprayingBecause the process of thermal spraying involves the atomization of molten metals, this produces large amounts of combustible dust and toxic fumes according to the publication of the Fabricators & Manufacturers Association, Intl. Other dangers involved with warm spraying are the fine metal particles that are possibly pyrophoric and can be very harmful when accumulated in the body, and the constant inhalation of highly toxic metal dust particles. The constant exposure to these fumes and vapors can produce serious respiratory diseases such as a coughs, pulmonary edema, asthma, or contact dermatitis. Some metals that are used such as nickel, chromium, or cobalt are considered to be potentially carcinogenic to humans.

In order to avoid or limit any of these hazards, there are certains standards and guidelines set  by the Occupational Safety and Health Administration. Safety being the priority, OSHA suggests your metalworking facility be fitted with the appropriate dust and fume extraction system to avoid any explosions and reduce metal fabricators exposure to metal air pollutants.

The Solution to Thermal Spraying Hazards

Imperial Systems CMAXX™ Dust Collector System can provide your metalworking facility with the protection it needs because our dust collector systems are designed for our DeltaMAXX™ Replacement Cartridge Filters. Our DeltaMAXX™  Replacement Cartridge Filters have the longest filter lifer, provide you with a greater cost in savings, and the cleanest air for your facility.  Here are more outstanding features the CMAXX™ Dust Collector System can provide for your metal facility:

  • Vertical cartridge design for a longer filter life.
  • 100% Total pulse distribution.
  • Best in class internal velocities.
  • Increased cleaning power with an energy efficient and high-performance manifold mounted pulse valves.
  • 15 Year manufacturer warranty
  • 10% More filter media than other same-sized vertical cartridge collectors.

At Imperial Systems, we know the hazards that metalworkers face each day, and we continue to go above and beyond the standards set by OSHA and the NFPA.  

Contact us today, and let us help you get fitted with the CMAXX™ Dust Collector System to combat the hazards of thermal spraying.

Sheet Metal Duct Fittings Done Right With Imperial Systems

Don’t choose sub-standard sheet metal duct fittings for your metalworking business. Save time and money by choosing Imperial Systems.

When the company first began back in 2001, Imperial Systems was strictly a fabricator of custom sheet metal duct fittings. Although Imperial Systems is now considered a manufacturer of industrial dust collectors, we are also still experts in custom duct and fitting jobs. Our pride in developing custom sheet metal duct fittings has always remained intact as we feel we are the best and most experienced in the industry with these custom jobs.

Why Choose Imperial For Custom Sheet Metal Duct Fittings?

sheet metal duct fittingsPaired with our outstanding customer service, we manufacture only the highest quality products that are reliable, durable, and guaranteed to last. Below are a few reasons why you should consider replacing your current duct and fittings with Imperial Systems:

  • Your current sheet metal duct fittings are in disrepair. Don’t let dust and fumes escape, causing your employees to be sick. Even more serious is the risk of combustion in the workplace.
  • You’ve noticed your employees getting sick more often. The cause may be leaky ducts and fittings. Look into replacing your current system with Imperial Systems’ trusted products.
  • Poor customer service. If you find that your current provider for sheet metal duct fittings is lacking in quality customer service, find out why Imperial Systems maintains trustworthy business relationships with our clients.
  • Your system is outdated. With an updated system regulated by OSHA and NFPA standards, you can save time and money. You may also reduce a risk of an accident or hazard.

We are often called upon to take jobs focused on ducting and sheet metal in addition to the dust collection systems we are best known for. Our standard of quality applies not only to dust collection but to the sheet metal duct fittings that enhance your current system so you know you’re in good hands.

When making a purchase decision in the metalworking industry, you must take into consideration both the quality of the product being purchased as well as the effectiveness and safety for the end-user–your employees. Today’s advances in dust collection systems have lessened replacement costs and injury or death due to faulty equipment.

Ready for Sheet Metal Duct Fitting Solutions From Imperial?

Don’t let your employees risk their health due to the fine dust particles that is a common byproduct in the metalworking industry. Keep your employees healthy and your environment safe with our quality sheet metal duct design work. Our ducts and fittings can be added to any current system you have, or we can replace your system with one of our highly demanded CMAXX™ Dust Collector Systems.

If you’d like to request a quote or schedule an assessment  based on your needs for a hardworking, high-quality sheet metal duct fitting which is both OSHA and NFPA regulated, get in touch with us today at 724.662.2801 or by finding out more about us.

At Imperial Systems, we specialize in advanced safety solutions you can count on.

The Cost of Procrastinating on Your Spark Arrestor Purchase

Delaying your spark arrestor decision may cost you– We can help you reduce the risk

warningHow much is your procrastination costing you?  In some industries, putting decisions or actions off for a later date can have negative, if relatively mild, consequences.  A deadline is missed, an opportunity is lost.  A client or partner may even be disappointed. While these consequences may be difficult for those having to deal with them, they pale in the face of the cost of procrastination within the metalworking industry.  

Unlike other businesses, your metalworking company is a high-stakes situation every single day.  With the potentially explosive combination of combustible dust and sparks flying, it is imperative that you act immediately to implement all of the required and recommended safety equipment, including dust collection systems with sealed ductwork and an effective spark arrestor.

Of course, each of these pieces of equipment represents a major investment for your business, and it is important to do your homework and decide which one is the best fit for your business.  However, letting that pending decision intimidate or hold you could be a serious hazard.  

In this blog, we will lead you through:

  • The Risks of Combustible Dust & Sparks
  • The Role of A Spark Arrestor in Risk Prevention
  • The Features & Benefits of the Imperial Systems’ Spark Arrestor

Understanding The Risk of Combustible Dust & Sparks

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what_materials_are_involved_in_combustible_dust_incidents_-_graphicIn the metalworking industry, it’s not secret that the materials you work with day in and day out can create a serious risk for combustion.  In fact, metals make up 20% of the materials involved in combustible dust incidents. And between 2008 and 2012, the United States Chemical Safety Board documented 50 combustible dust accidents, which led to a total of 29 fatalities and 161 injuries.

 

Unfortunately, as of 2014, metals and manufacturing were among the top industries being cited by OSHA for combustible dust, flammable dust, and other explosible dust hazards. This tells us that, although the risk is clear, it may not be clearly understood by those in the industry.

Five simple elements are required for combustion to occur:

  • Heat
  • Fuel
  • Oxygen
  • Dispersion
  • Confinement

image-300x275With each of these factors occurring effortlessly within most metalworking shops, tragedy lurks only a moment away.  This is why, in 2006, the US Chemical Safety Board recommended a comprehensive combustible dust regulatory standard for all industries, be added atop the initial regulations which were developed in the grain industry in 1987.

Clearly, the risks are both real and nearly ubiquitous.  They need to be taken seriously by all within the affected industries. One of the best ways to do this is to evaluate your workspace and ensure that it has all of the equipment necessary to meet OSHA, NFPA, and other regulations.  Additionally, you should regularly evaluate your equipment to ensure that it is in good working order.  

The Role of A Spark Arrestor in Risk Prevention

At its most basic, the role of a spark arrestor is to prevent the emission of flammable materials from combustion.  Sparks, in various forms are the major cause of combustion in combustible dust accidents:

Screenshot at Jan 07 19-37-37Because sparks are often carried along through the exhaust gas stream, it has not cooled from its temperature of 600 degrees Fahrenheit by the time it arrives at the solids separator.  At this point, it can be deposited onto the filter element surface, positioned as a glowing risk of combustion. The filter element surface is at high risk for combustion, no matter what material it is made of, because of it’s role in collecting tiny metal particles and dust that are produced by nearly every manufacturing and metalworking process.  Even a simple spark is enough to insight disaster.

This is why OSHA’s ignition control recommendations regarding combustible dust include the following:shutterstock_243589588

  • Control smoking, open flames, and sparks
  • Control mechanical sparks and friction
  • Use separator devices to remove foreign materials capable of igniting combustibles from process materials
  • Separate heated surfaces from dusts
  • Use an equipment preventive maintenance program.

OSHA’s injury and damage control methods also include:

  • Separation of the hazard (isolate with distance)
  • Segregation of the hazard (isolate with a barrier)
  • Deflagration isolation/venting
  • Specialized fire suppression systems
  • Explosion protection systems;

A Spark Arrestor is an instrumental part of these methods, working to minimize risk by cooling and thus extinguishing sparks before they reach the filter surface.  In the diagram below, note how the hot spark enters the arrestor which both cools and collects debris, before allowing the cooled ember to pass through.

Spark Arrestor internal view copy

The spark arrestor fits within the full dust collection system as the first line of defense.  They take up little or no extra space, but provide powerful results.  

The Features & Benefits of the Imperial Systems’ Spark Arrestor

At Imperial Systems, our highest priority is to provide the best solutions in dust collection and air pollution.  We are determined to provide the best protection for your workers, your plant, and the environment.  For over a decade, we have been serving metalworking businesses like yours all over the United States and Canada.

In an effort to provide fully comprehensive dust collection equipment, we have debuted our Spark Arrestor.  It’s standard features include:

  • Heavy duty construction
  • No maintenance
  • Clean-out door
  • Fully welded construction
  • Easy install into any system
  • Can be installed in horizontal or vertical configurations
  • No moving parts
  • Carbon steel or stainless steel available
  • No water required
  • AVAILABLE IN SIZES: 6 in. to 40 in

Additionally, you can opt for raw inlet and outlet edges, rolled angle flange for bolt together ducts, or clamp together for clamping duct.

As with all Imperial Systems’ products, you can count on the highest quality materials, top safety features, and unbeatable value.

The Cost of Procrastination

So back to our original question.  If you haven’t yet decided on a spark extinguisher for your metalworking business, what is that procrastination cost you?  Let’s take a look at the numbers:

From 1996-2005, 106 explosions resulted in 16 fatalities, 126 injuries, and an estimated cost of $162.8 million in damages to the facilities.

And we know, from previously cited studies, that sparks are a major cause of such explosions.  Will you absolutely face a combustible dust explosion if you put off your decision about a spark extinguisher?  Perhaps not.  But is it really worth the risk?

If you are ready to take the next step towards improving the safety of your workplace with an industrial spark arrestor, you can contact Imperial Systems today at 800.918.3013 or by emailing us at info@isystemsweb.com.
At Imperial Systems, we know that spark collection is only one of the many challenges that metalworkers like you face every day.  What other safety and production challenges are you facing in your business?  What actions have you taken to try to solve these issues?  Share your ideas and experiences with us in the comments section below.  

22 Facts You Don’t Know About Ductwork (But You Should)

Discover the customized ductwork solutions you need.

IMG_0787Here at Imperial Systems, we’ve been manufacturing customized sheet metal ductwork since 2001.  With all that experience, we feel proud to call ourselves experts in the industry.  However, a lot of the individuals and businesses we serve know that they need a customized ductwork solution, but they don’t know that much about the product itself.  This can be a major problem for businesses or individuals who are trying to make a serious investment in their business and its safety, when they are unable to determine exactly what they need and who can best help them reach their goals.

So, we want to share our expertise with you!  Discover the practical–and sometimes entertaining–facts about the world of ductwork fabrication and installation.  

Interesting Fun Facts About Ductwork

 

  • Let’s start simple: ductwork is one word. Despite the countless times it’s misspelled as two words, it really is just one word.
  • Sheet metal bending isn’t as old as you think it is.  Manufacturing and production using the material really took off in the late 1800s during the Industrial Revolution, as assembly lines and new machines made it a practical and profitable endeavor.
    http://www.sheetmetalblog.com/
  • Ductwork is an Imperial Systems tradition.  In fact, we started as a custom sheet metal ductwork before our industrial dust collectors!  With that kind of experience, we’re confident that we’re still the best in the industry.
  • There are 3 main techniques for bending sheet metal: Bottoming, Coining, and Air Bending.  Each method uses different tools to bend sheet metal for all sorts of purposes… including ductwork.
  • Stiffening is a key component to ductwork compliance.  In fact, the SMACNA sheet metal standards call for ductwork of different gauges to be stiffened to ensure it will be durable and not warp during operation.
  • Round ducts are stiffened differently than rectangular ones.  Round ducts receive stiffening ribs at equal intervals.  Rectangular ducts receive cross-braking and beading techniques, depending upon the machinery used and the intended application.
  • We offer HUNDREDS of different ductwork components.  We know different parts are necessary for different applications; you should know that we’ve always got you covered. You can check them all out in our full catalog.
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  • Imperial Systems Professional Shots 065Whether you’re a food processing company or a major basket maker, we’ve got you covered.  That’s right, baskets.  When the Longaberger Company needed new, highly efficient ductwork for their new building, they reached out to Imperial Systems because of our prices, services, and expertise.
  • Fabricated Gore Elbows are our most common elbow.  Thanks to their versatility and the adjustments that can be made to the radius based on application, we use this elbow in virtually every industry.
  • Our Floor Sweeps are hands free.  To operate the hinged door that seals off the air flow when not in use, we added a lever on the side of the door that can be operated by foot.
  • Heavy wear applications don’t slow us down.  Our heavy duty flat back elbows are a square constructed elbows with a 10 ga. housing and a ¼” plate back which can be either welded solid or bolted for replacement without removing the whole elbow.  This heavy duty construction makes them perfect for the toughest of applications.      
  • The most common ductwork material is carbon steel, but it isn’t your only option.  Our fully welded pipe comes in galvanized, stainless, and painted.
  • You could crawl through our ducts… but you probably shouldn’t.  All of our welded pipe is smooth inside and free of burrs and rough edges.   So, if you’re on a super spy mission, you don’t have to worry about skinned knees.  But unless you actually on a secret mission, you should probably keep your feet on the ground.
  • Good ductwork is dust collection’s best friend.  The ductwork of an industrial dust collection system connects its hoods, air cleaning device, and fan.  You can have the best device in the world, but if your ductwork is poorly constructed or improperly sized, you’re not going to get the results you need.
  • Ductwork for dust collection is different than ductwork for HVAC or fume extraction.  Tapered systems are typically used with dust collectors, while plenum systems are used more often for HVAC systems, and occasionally for fume extractors.
  • When choosing ductwork for industrial dust collection, you need to answer three key questions.  Industrial Ventilation, Inc. recommends asking the following three questions (and we completely agree.)  What exhaust volume is required at each dust collection point?  What particulates are being collected?  What are the conveying velocity requirements?
  • Dirty ductwork could be costing you.  Over time, debris can accumulated in the ductwork of industrial dust collection exhaust systems, decreasing their ability to perform at the optimal level.  In fact, a buildup can lead to a loss of up to 42% efficiency!  Poor performance can lead to major problems, including health problems in employees and higher running costs.
  • It’s not just the dust collector… your ductwork has to meet NFPA standards too. If your industrial duct system is being used for dust collector exhaust, it is imperative that it meet these standards.  Ensuring that your system has adequate conveying air velocity for the load it will be handling is imperative to avoiding debris buildup in ducts and reducing the risk of explosion.ComDust-Pentagon-1000
  • You don’t necessarily have to look inside ducts to identify areas of dust accumulation.  In fact, there are a number of telling visual clues you can look for, including:

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    • A main duct diameter that doesn’t enlarge after branch junctions
    • A branch duct joining the main duct at a T junction
    • A main duct that is blanked off
    • A ductwork system that includes too much flexible hose
    • A smaller diameter duct abruptly joining a larger diameter one
    • A duct blast gate that isn’t locked in position

 

  • You don’t have to be an expert in ductwork.  Although these facts are certainly a great starting place, you don’t need to be an expert in the world of customized ductwork to get the products you need to keep your business running safely and efficiently.  Instead, you can work with the experts at Imperial Systems.  Just tell us about your business and what needs you are trying to meet; we’ll help you select or design the perfect solution for you.

Now that you’ve learned a little bit more about industrial ductwork, you may be wondering if your company’s ductwork is actually up to par.  Or, you may know that it’s time for an upgrade or other major change.  No matter what stage you are in, let us
Have questions about any of the facts you read today?  Let us know in the comments section below, and we’ll get back to you as soon as we can!  If you have specific products about how our products and services may be able to help your business, give us a call today at 800.918.3013.

The Domed Roof Design: The Solution to Your Worst Dust Collection Problems

Did you know that 30,000 US manufacturing facilities are considered at-risk for explosion by OSHA?

The Structure of a Dome: What’s to Like?

Side-View-Doors-Open-CUTOUTA domed roof design has been called “the king of all roofs”, and they support that name by covering many of the world’s most important and famous buildings. What is a dome? Domes have a curved structure, without corners, angles, or supporting columns. The design options for domes are many. You may see a dome on private homes, commercial buildings, or governmental and religious edifices.

Lightweight yet self-supporting, the dome provides a focal point and a natural attraction. In buildings, the airy dome structure creates an atmosphere evocative of pre-historic civilizations. Indeed, the dome’s deeply rooted origins in many cultures of the ancient world brings an air of richness and sophistication.

Design, quality and function combine to make this architectural structure a winner no matter where or what you’re building. And these observations hold true not just for buildings, but also for technology. What we refer to is industrial manufacturing. In many industries, the domed roof design has been shown to provide many benefits in the building. At Imperial Systems, we wanted to take the ingenuity of the domed system just one step further. For a quintessential dust collection system, we offer dust cartridge collectors with a superior domed roof design, providing industrial manufacturers with the many benefits of a long-lasting and safe instrument.

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CMAXX Offer a Superior Domed Roof Design

CMAXX offers a superior domed roof design for cartridge dust collectors, providing a solid roof to increase efficiency. The roof on the CMAXX has a domed structure to make water run off and to improve the strength of the unit. These changes mean that the CMAXX is the only dust collector equipment that does not require external bolt holes. What does it include?

CMAXX domed roof design  = NO bolt holds; NO individual panels; and NO roof seams!

 

How CMAXX Stays Ahead of the Competition

Front-View-Straight-On-with-badgesIndustrial manufacturing requires instruments that can endure tough conditions, lasting for years and producing a high-quality material, all the while maintaining safety for those who use these instruments. That’s a tall order. At Imperial Systems we are interested in producing the best technologies, using scientific innovations as well as lessons from the past to create an equipment that will hold up to the pressures of your work. Safety equipment, such as cartridge dust collectors, must especially be designed to endure harsh environments.

Compared to the competition, the CMAXX domed structure excels in every way. If you research a similar unit without the domed roof design, you’ll discover a 16-cartridge dust collector with about 160 bolt holes and 1000 holes spaced throughout the collector. This design represents the old style of industrial fabrication, and the bolted panels hold water, leading to leaks and rusting and freezing. All these conditions signify damaged equipment for you.

But check out our the alternative!

 

Domed Roof Dust Collector Technology: A Challenge to the Status Quo

We know already that weather can be the most unpredictable and difficult element to control when it comes to producing safely and efficiently. At Imperial Systems, we’re not content to until we can provide you with the best for your manufacturing needs. The harsh external elements have resulted in warping, rust, leaks, and other problems for many metalworking and other industrial manufacturers. But your livelihood and the success of your business depends upon decreasing the instances of these types of problems. And the best way to eliminate the flaws in your production is to go back to its source: equipment.

The defects produced by your equipment can compromise the integrity of your unit. This undermines the safe environment you are seeking to create! Thus, we suggest that you confront these problems using a new and reformed dust collection system technology. We use four features to guarantee your protection against leaking and water damage.

  1.     Positive Bow. The shape allows debris to run off more easily with water so that the unit becomes easier to clean. This inhibits pooled-up water from freezing on top of the unit, causing damage.
  2.     One-piece Roof. Eliminating the individual-panel design, the one-piece roof offers a design that will be strong against leaking and warping.
  3.     Zero Bolt Holes. The system is sealed because we have eliminated the external bolt holes altogether. Now, you can rest assured that you will not have to deal with rusty bolts, leaks, and breaking parts.
  4.     A Strong Frame. The 3/16” roof is thick, fully welded, and the welds have been ground smooth. And, 1/4’” plate internal stiffeners offer the additional benefit of a reinforced structure.

What are the Biggest Threats to Dust Efficiency?

We believe that our domed dust collector structure presents a solution to the biggest challenges in the manufacturing business. The above-described features account for the major problems that will confront every industrial manufacturer: combustion, exposure, and pollution.

  1. Combustion.  Fire explosion is a primary hazard that can only be avoided by preventing the build-up of dust particles. Employees should also be aware of the locations of the nearest fire extinguishers and the exit protocol in case of an emergency. While new OSHA guidelines have decreased the number of fires occurring in industrial plants in the U.S. it is estimated that there are still 30,000 facilities at risk for dust combustion.
  2. Exposure. According to the Vision Council, 61% of reported eye injuries occur in trade, manufacturing, and construction jobs. The eyes are exposed to chemical fumes, metal, dust, concrete, and other particles that can be injurious to the worker. Besides affecting the eyes, chemical exposure is also dangerous to the nervous, reproductive, and urinary systems. For these reasons, employees should always wear their personal protective equipment such as eye goggles and dust masks. A well-built dust collector decreases these risks by decreasing the amount of material that can exit the system.
  3. Pollution. When there is a high concentration of dust, smokes, and particles in the air, this affects the ability to breath. Inhalation of such particles can cause damage to the major organs and cause other health problems. Dust in particular can cause breathing problems, injuring the lungs and aggravating any health conditions the worker may already have. The presence of dust in the air is also a predictor of accidents, as the worker is less able to see in these environments.

 

Invest in Quality.

The domed roof design dust collector provides a one-piece structure that protects your workers against leakage and damage. With many risks at stake, it’s important to consider the best options for your company so that you can avoid being another explosion statistic! For more information or questions, please talk to us at Imperial Systems. We are available to help you decide the best dust collector for your current needs.

How Evenlock Technology Sets Imperial Systems Apart from the Competition

EvenLock Technology from Imperial Systems empowers you to effectively prevent hazardous leaks from developing anywhere across filter gaskets.

At Imperial Systems, we design and manufacture our dust collection equipment with EvenLock  Technology because we understand the concerns of the metalworking industry.   

Whether your manufacturing business is devoted exclusively to metalworking or that is just a part of the larger work you do, you undoubtedly have a strong understanding of one of the highest concerns in the industry: safety.  Even without the multitude of variable brought on by the presence of human workers, the dust, fumes, and sparks that result from standard metalworking processes can be cause for concern.  These elements, if allowed to mix without the control of high-performing safety equipment, could quickly become a recipe for disaster.

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The absence of adequate safety equipment like Dust and Fume Collections Systems with Spark Arrestors can lead to some of the most dangerous work hazards in the nation.  A 2008 CBS News report enumerated some of the most recent examples of this problem:

  • At least 30,000 U.S. factories are vulnerable to dust explosions
  • 350 dust explosions occurred in U.S. factories between 1980 and 2008
  • During that time 133 people were killed and many more injured

These numbers, though staggering on their own, only begin to reflect the dangers of inadequate dust and fume collection systems.  In addition to these large scale disasters, ongoing dust or fume problems can also lead to health problems in workers, malfunctioning equipment, inefficiency, and losses in time, productivity, and money for the businesses involved.

http://www.cbsnews.com/news/is-enough-done-to-stop-explosive-dust/(@CBSnews)

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Many manufacturers, have taken the initiative to establish dust collection systems, spark arrestors, and other safety equipment into their work areas.  However, potential danger may be lurking in these systems, disguised by the illusion that the problems of dust, sparks, and fumes has been solved:

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1Hazardous Leaks From Unclean Filter Gaskets

As Robert Brooks of EHS Today (@EHSToday) points out, filters need regular, effective cleaning to continue operating at peak efficiency.  Insufficiently cleaned filters can lead to a loss in suction which not only lowers the efficacy of the system but can also lead to uneven gasket compression on the filters.  This uneven compression can lead to leaks occurring in the filter gaskets which, left unattended, can undermine the work of the system.

http://ehstoday.com/industrial-hygiene/when-dust-settles-how-choose-dust-and-fume-collector (@EHSToday)

Other industrial dust collection system manufacturers have tried to address this problem in their own products.  Two of the most common approaches are:

  • Individual door pans with hand crank knobs
  • Cam-bars that rotate to clamp the filter in place

Although these “solutions” are common, the reality is that both of them fall short of the mark and, ultimately, are ineffective to solve the problem of hazardous leaks occurring across filter gaskets.  The hand crank knobs on individual door pans can easily be lost or stripped out, leaving you in need of a potentially costly, time-consuming replacement.  Cam-bars which rotate to clamp down on the filter are unable to deliver the same level of compression–if any at all–to the rear filters of the collection unit. Clearly, a new solution is necessary.

2A New Solution: EvenLock Technology From Imperial Systems

At Imperial Systems, we are dedicated to providing the highest level of quality, safety, and value in each one of our products.  This means that we aim to design and manufacture solutions that metalworkers like you can rely on.  We are not content with products that are easily broken or unreliable.  So, we set out to create the best solution for the problem hazardous leaks occurring across filter gaskets within our industrial Dust And Fume Collection Systems.

 

 

We are proud to announce that EvenLock Technology is an incredible breakthrough filter cleaning technology that ensures even-gasket compression on all cartridge filters in our CMAXX Industrial Dust Collection System.  By compressing the DeltaMAXX filter gaskets at a 50:1 compression rate, and by employing individual cams at each filter, from the front to the back, our system ensures 100% literal “Even-Locking” across the board.  With our new EvenLock Technology, manufacturers can finally, effectively prevent hazardous leaks from occurring anywhere across the filter gaskets.

EvenLock Technology Advantages

This advanced technology comes with several advantages that set it–and Imperial Systems–apart from the competition:

  • This technology eliminates the torsion effect from a rotating bar that is likely to twist in-motion and not deliver the same compression, if any, to the rear filters.
  • EvenLock Technology works just as well with loaded heavy filters; if the slide rail arm is locked forward, your gaskets are protected.
  • Our EvenLock Technology comes standard in every CMAXX Industrial Dust Collector, so you can have confidence in all of our equipment.

This unique approach is the solution manufacturers need to address the challenge of potentially problematic leaks in the system.

CMAXX  Features and Benefits

3If you are currently using an industrial dust collection system that does not have Imperial Systems’ EvenLock Technology, it may be time to make a change.  This advanced technology is just one of the many advantages of our CMAXX Industrial Dust Collection Systems.  This vertical cartridge dust collection system is designed with revolutionary PD Technology for Maximum Cleaning Performance. Other favorite features include:

  • A low-profile design to save space
  • Vertical cartridge design to promote a longer filter life
  • Tool-free, heavy duty filter doors for shorter service time
  • No external bolts for less chance of water and air leaks
  • 100% total pulse distribution across filter media
  • Spark Trap features

4This system is designed to be used with our DeltaMAXX replacement cartridge filters.  Made with advanced nano-fiber technology, these filters offer up to twice the filter life of the industry standard. They can also boast a MERV 15 Filtration Efficiency, the best in the industry, along with less pulse cleaning and lower operational mass emissions.

 

Together, these products have the best cleaning efficiency and offer the longest filter life in the industry, saving you time and money while still providing the highest level of service.

 

In Conclusion

In this blog, you found just a few examples of the types of solutions that Imperial Systems regularly provides to metalworkers and manufacturers like you. 6 All of the products that we design, manufacture, and install are engineered for outstanding quality, safety, and value.  We also maintain a large inventory of our dust collection equipment, so that we can ship most of the products you need–including the CMAXX Dust Collection System with Evenlock Technology–within 24 hours of your order. For years, we have earned credibility and established strong relationships as a provider of customer-driven solutions.

 

 

And now, we want to hear from you.  What are some of the biggest challenges you face in metalworking or in other aspects of your manufacturing work?  What problems do you face regularly for which you wish you had a solution?  At Imperial Systems, we are dedicated in creating products to answer the needs of manufacturers like you, so we look forward to hearing from you.  Please leave your thoughts, questions, or concerns in the comments section below!

The In-Line Spark Trap Options You Really Need

The Imperial Systems Spark Arrestor is your best choice for an in-line spark trap that you can rely on for quality, value, and safety.

Just over a decade ago, metal fabricators were considered the third-highest at-risk group in a lineup of metalworking industry safety statistics by the U.S. Department of Labor’s Bureau of Labor Statistics.  One of the major risk factors posing a hazard to workers is the combination of dust, fumes, and sparks that are all put off during manufacturing processes.  However, with the right dust collection equipment, you can significantly reduce the chances of illness, injury, or accident occurring in the workspace.  So, an important question to ask yourself right now is: do I have the right in-line spark trap to keep my workers safe?

In-Line Spark TrapAt Imperial Systems, we are acutely aware of the importance of an in-line spark trap, or spark arrestor, that you can rely on to extinguish all sparks before they enter your industrial dust collector.  This is why we have designed and manufactured two different options to help your business stay safe.

Dust Collectors With An In-Line Spark Trap

Our CMAXX Laser and Plasma Fume Extraction System incorporates all of the latest metalworking safety technology and is easy to use.  It comes with a built in in-line spark trap to ensure that any spark which enters the collector is immediately extinguished.  Additionally, this system also offers the following advantages:

  • Premium reverse air cleaning
  • DeltaMAXX fire retardant filters
  • Fan silencer
  • Tool-free filter access and change out
  • Pre-wired setup: all you have to do is plug it in and push start!

 

Additional Spark Arrestors

Of course, at Imperial Systems, we acknowledge that you may not be prepared to purchase and install a new system, no matter how easy it is, in order to get the in-line spark trap you need. So, we also sell individualized spark traps, called Spark Arrestors, which are customized to fit your unique needs.

Manufactured with the same attention to quality, safety, and value as all of our products, these offer the following features:

    • Heavy duty construction
    • No maintenance
    • Clean-out door
    • Fully welded construction
    • Easy install into any system
    • Can be installed in horizontal or vertical configurations
    • No moving parts
    • Carbon steel or stainless steel available
    • No water required
    • Available sizes: 6in. to 40in.

For more information about either of these quality spark trap options, you can give us a call today.  One of our experienced service representatives will help you to find the perfect solution for your metalworking business.  Begin the conversation by calling 800.918.3013.

In-Line Spark Trap | In-Line Spark Traps

Why You Won’t Survive Without An Industrial Dust Control Company

The metalworking industry can be a risky and sometimes fatal, business. Let Imperial Systems pave your way to safety.

Industrial Dust Control CompanyIn January of 2003 there was a polyurethane dust explosion caused by dust accumulation on the ceiling of a pharmaceutical plant in Kentucky, where 6 lives were lost and 38 were injured.

Surprisingly, many facilities think that it will never happen to them. Their employees will stay healthy and safe, as long as they are following the guidelines and rules of the company. Have you ever thought about the guidelines and rules your industrial dust control company is following?

Injuries And Fatalities Follow Improper Dust Control

In February of 1999 a dust fire in a plant in Massachusetts killed 3, injured 9. The reasons for explosion were lack of dust control, inadequate ventilation system design and lack of maintenance of ovens and safety devices.

Understanding Combustible Dust Explosions

Just because there is dust lying around, doesn’t mean that there is going to be an explosion. If that is the case, most of our homes would have exploded a long time ago. In the metalworking industry, the situation is not the same. The importance of hiring a thorough industrial dust control company is imperative for a safe, reliable facility.

Combustible dust fires occur when fuel, heat and oxygen are present. Commonly called, “The Fire Triangle”, there are 2 factors in addition to this triangle.

  1. Dust particles must be in heavy concentrations
  2. Dust must be partially confined to one area

Combustible dust ignites and burns at a mind-blowing rate, when confined, due to the inability to diffuse from proper ventilation.

An industrial dust control company will look for potential hazards in your facility.

5 Potential Hazards In Your Metalwork Facility

  1. There is presence of combustible dust that may be released into the air
  2. Materials are processed into tiny particles
  3. Areas that dust can accumulate for a long period of time are present
  4. Activities that the consumption or production of combustible dust is present
  5. A reason that dust will find a source for ignition

With a leading industrial dust control company like Imperial Systems, you will receive quality service and products ensure that hazards will be controlled. Imperial Systems carefully follows strict OSHA guidelines with production of all products.

Some of our products include:

  • CMAXX Dust Collector System – designed with cutting-edge PD technology, it has 10% more filter media than other filters, to allow maximum cleaning performance.
  • DeltaMaxx Cartridge Filters – With 2x the filter life of standard filters, DeltaMaxx is made from Nanofiber technology that prevents submicron particles from being embeded in the media.
  • CMAXX Laser Fume Extraction System – Completely wired from the factory, all you have to do is plug it in and press start. With the same guarantees as the CMAXX Dust Collector, you won’t be disappointed.
  • Duct and Fittings – Imperial Systems delivers a variety of duct and fittings, all custom to fit your system.
  • Spark Arrestors (Traps) – With heavy duty construction, customizable fittings and material, easy install and no water requirement, your satisfaction will be met.
  • And more!

Quality Service Guaranteed

We cannot tell you the type of equipment or service the above companies received, before these explosions and fatalities happened. What we can tell you, is that our service is guaranteed.

Imperial Systems will inspect each product, and personally install the equipment in any facility. Our dust collectors require minimal maintenance and if maintanence ever is needed, our experts here at Imperial Systems is here to help.

When looking for Industrial Dust Companies in your area, remember that Imperial serves over North America in both the United States and Canada.

If you would like more information on the different options we have available to you, call 1-800-918-3013.

Industrial Dust Control Company | Industrial Dust Control Companies