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Nanofiber Filters Served With Sawdust?

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Nanofiber Filters Served With Sawdust?

SHOULD YOU SERVE NANOFIBER WITH SAWDUST? A CHART FOR THE DISCRIMINATING FILTER HOST

 

Most everyone knows you can’t just go mixing any kind of filter with any kind of dust. After all, some of them certainly don’t pair well together. Fortunately, we here at Imperial Systems have put together a guide for the thoughtful buyer of dust collection filters. With this handy reference, you’ll never have to worry about showing up with the wrong filter for the occasion!

 

(NOTE: We DO NOT recommend that this be used as a substitute for consulting with an actual filter expert. Please call us At 800-918-3013 for important information that doesn’t fit in an infographic.)

nanofiber

A BIT OF CLARIFICATION:

  • Filter bags, or sometimes cyclones, are usually used for materials that are large, fibrous, or big enough to damage a cartridge filter. Bags are also often used when the temperature or humidity is too high for a cartridge filter to handle.

 

  • Metalworking or welding produce fumes. These are very fine particles and an 80/20 media is not efficient enough to catch them. Since many metal dusts are explosive, we do recommend a DeltaMAXX™ nanofiber FR, which is fire retardant. In some applications such as shot blasting, spunbond is used because it is very durable. If your metal fume or dust has grease or oil in it, you may need a special media.

 

  • Dust from ANY of these categories can be explosive. If your dust is explosive or flammable, we will almost always recommend a DeltaMAXX™ nanofiber FR filter as part of an IDA system.

 

  • Organic dust, like food products, may present some special challenges. Organic dust comes in different sizes, and may clump together, absorb moisture, or present other particular problems. Please consult with us about the characteristics of your particular dust.

 

  • If your dust is oily, abrasive, wet, sticky, or otherwise likely to make a mess of a normal dust collector filter, there are a variety of special materials to help. PTFE resists having anything stick to it, while hydrophobic or oleophobic filters will repel water or oil.

 

AGAIN… THIS IS IN NO WAY MEANT TO SUBSTITUTE FOR TALKING TO A FILTER PROFESSIONAL. PLEASE CONSULT WITH ONE OF OUR KNOWLEDGEABLE TEAM MEMBERS BEFORE MAKING ANY QUESTIONABLE FILTER DECISIONS.

800-918-3013

Energy Cost Savings Through Your Dust Collector

HOW YOUR DUST COLLECTOR CAN PAY FOR ITSELF

Installing a dust collection system (or updating an old one) is a big investment. Safety, health, and compliance are all important reasons to do so.  Will energy cost savings with this investment benefit your company in the long run? When a company is looking at spending that kind of money, it helps to be able to talk about a more immediate return on your investment.

 

The good news is that your new system can pay for itself in as little as two years by saving you a lot of money on heating and cooling costs.

energy cost

It’s hard to put a dollar amount on employee health, but it’s easy to put a dollar amount on how much you spend heating and cooling your building. If you’re spending that money and then venting heated air outside the building, you’re effectively blowing money out the window.

 

Many of our CMAXX systems have paid for themselves within two years just in energy cost savings. And they will continue to save their owners money for many years of service. Some companies have even been able to find energy conservation incentives that save them money on the immediate cost of a system.

 

Recirculating air back into the facility can be an excellent cost-saving measure, but only if it doesn’t compromise the health of people working there. This means that the recirculated air has to be completely clean and safe.

 

If you’re planning to recirculate air, it’s important to make sure that your system is equipped to handle the type of dust you’re producing. Particles from welding fumes and laser or plasma cutting smoke can be as small as half a micron. This usually requires a filter with a rating of at least MERV 15, meaning it is more than 95% effective for particles down to 0.3 microns. If there might be dangerous or highly regulated materials (such as hexavalent chromium) in the dust, a HEPA filter may be necessary for air that’s going to be returned inside.

 

Besides the savings on energy costs, a system that recirculates air can actually be more efficient. In some ambient systems, the clean air enters at the level where people are working, which moves the dirty air out of the work area and toward the collector. These types of systems are very effective at filtering the air in larger spaces.

 

If a dust and fume collector is something you’re going to need anyway, the tremendous savings in  your energy cost might be what it takes to get that project into the budget. After all, those heating and cooling cost savings will go back into the budget year after year, and that’s something everyone likes to hear.

Whistleblower Dilemma: Your safety or your job?

Afraid to report unsafe work conditions at your work site?  OSHA can protect you from retaliation.

It is a known fact that many workers are forced to work in unsafe environments.  Although most companies strive to provide safe and healthy working conditions for their employees, there are some places that are unwilling to make worker safety a top priority.  If you know you are in a situation where your safety and others that work with you is at risk, you may have fears of losing your job if you bring it to anyone’s attention.

safety

The stigma of being a Whistleblower is not what it used to be in the past.  In fact, OSHA has a program in place that protects your rights as an employee.  Such provisions include:

  • The right to file a safety complaint to OSHA
  • Protection from employer retaliation, such as termination
  • The right to participate in OSHA inspections and talk to the inspector
  • The right to review employer exposure and/or injury records

OSHA has fined many corporations due to unfounded termination of employees who report safety violations.  It is simply against the law, and in the end, costs the company more than just fixing the safety problem itself.

Keep in mind that sometimes it may not be a malicious intent by your employer.  They may not be aware of safety issues that concern you.  How do you approach this situation?  Read this informative article that gives you tips and advice about talking to superiors with confidence.

All in all, there are many options for shop and factory workers to be part of the solution in making their job safe.  Click on the links below if you have questions or want to learn more about safety in the workplace.

 

http://www.whistleblowers.gov/index.html

https://www.osha.gov/workers/index.html

OSHA NEWS:     http://bit.ly/2bX9j1E

Industrial Dust Control Solutions: Why It Matters

Whether you are a new manufacturing business or just branching out into new territory, if you are going to get into the metalworking field, addressing industrial dust control solutions demand some serious consideration. Not only do you have the safety of your work space to think about, but unchecked dust and fumes can also pose health hazards to those working in it. We’ve spent nearly 15 years considering the challenges of industrial dust accumulation and control, and we have developed the solutions our customers need.  Discover the facts you need about dust control for your business to keep things running safely and smoothly.

Meet Safety Standards

industrial dust control solutionsAn accumulation of dust in any industrial setting poses a threat to the health and safety of those working there.  This is especially true in the world of metalworking where the fine dust particles may be especially toxic.  In light of this threat, the Occupational Safety and Health Administration (OSHA) has established standards of safety that must be followed in any such industrial settings.  These address not only dust that may be inhaled but also the threat of combustibility through its accumulation.  Check out the latest combustible dust update HERE.  When you look for an industrial dust control system, begin by ensuring that it meets these and other industry standards.

Anticipate Dust And Fumes

As you consider a system to provide dust control for your work space, make sure you take fumes into account as well.  In many metalworking processes, noxious fumes are created which are more than unpleasant; they can be increasingly harmful when inhaled.  Not all industrial dust control systems are created to handle this dual threat, so it is vital to choose a collector that can manage both dust and fume generated by metalwork manufacturing.

Your Industrial Dust Control Solutions Experts

Whether you need dust and fume filtration or just a dust collection system, Imperial Systems is your industrial dust control headquarters. We manufacture the most efficient, strongest and longest-lasting systems and filters in the industry.  Through these products, we have become well known for our dedication to quality, value, and safety.  Our outstanding line of equipment includes:

  • CMAXX™ Dust Collector System
  • DeltaMAXX™ Cartridge Filters
  • CMAXX™ Laser Fume Extraction System
  • Spark Arrestor
  • Explosion Isolation Valve
  • Custom Ductwork & Fittings
  • Heavy Duty Abort Gates
  • and more!

Most of our products are available to ship within 24 hours.  For more information about our products and how we can support your metalworking business, contact us today.

Dust Explosions: The Hidden Hazard

Dust explosions are bad to begin with, but what do you know about secondary explosions?  There are many factors that determine how likely a particular type of dust causes a deflagration. When you think of combustible dust, do you think of the explosions you’ve heard about at grain handling facilities? Maybe you think of the explosive potential of aluminum dust.

 

Three dust explosions that occurred in 2003 demonstrate how many different types of production and manufacturing can produce a deflagration risk (http://www.fireworld.com/Archives/tabid/93/articleType/ArticleView/articleId/86899/DEADLY-DUST.aspx). In a North Carolina plant, the accumulated dust came from a polyethylene coating being applied to rubber. As the material dried, dust was formed and accumulated above the work area. Even though the work area itself was very clean, a layer of dust a quarter of an inch thick was enough to cause an explosion that killed six people. In this situation, a dust collection system in the production area could have captured the dust particles as they came off the material, before they were allowed to circulate through the facility.

dust explosions

The explosion in Kentucky was caused by combustible dust that resulted from a resin used to treat fiberglass. Workers were aware of the large quantities of dust, but cleaning processes often just caused more of the dust to become airborne, and it accumulated in the ductwork and in dust collection equipment. There were no safeguards in place to prevent a flame front from traveling through the ductwork or getting into the dust collector. An abort gate with spark or flame detection could have identified and stopped the fire from spreading, and dust collectors designed to stop deflagration fronts could have prevented the dust collectors from becoming sites of secondary explosions.

 

The explosion in Indiana was fueled by aluminum dust from scrap processing. The dust collector in this case was the source of the explosion. It did not have explosion venting, and instead of being directed safely, the explosion traveled back into the building and ignited dust in the ductwork. A secondary explosion occurred when dust accumulated on surfaces inside the facility ignited. A dust collector designed to isolate and redirect a deflagration could have prevented this accident.

 

The National Fire Protection Association, which establishes many of the codes and standards for handling potential fire hazards (http://www.nfpa.org/codes-and-standards/all-codes-and-standards/list-of-codes-and-standards) recommends that all dust collection systems should have explosion venting to redirect explosions and abort gates or other equipment to stop flame fronts from spreading. It also recommends improved housekeeping measures to prevent dust from accumulating, which may be accomplished by collecting dust at the source so it cannot accumulate in difficult-to-reach places.

 

It’s often this accumulated dust, hidden on high surfaces, in corners, or inside ductwork, that ignites to cause a secondary explosion that’s far more dangerous than the original one. Witness reports of dust explosions often include descriptions of a smaller explosion followed by one or more larger ones; this is secondary ignition (https://www.osha.gov/Publications/osha3791.pdf). Dust control throughout the entire facility, along with fire prevention equipment such as abort gates, spark arrestors, and explosion venting, can control a potential explosion and prevent a small fire from becoming a fatal disaster.

Welding Fumes: Your Toenails Hold Clues

WELDING FUMES MEET “CSI”: WHY SCIENTISTS ARE COLLECTING WELDERS’ TOENAILS

A group of researchers interested in exposure to metals in welding fumes come to your workplace to collect samples. You might think they’d be there to test the air quality or to take samples of fumes or dust. These researchers didn’t come to do any of those things. The only equipment they bring with them: paper envelopes and toenail clippers.

That’s right… these researchers are here for your toenails.

That’s how researchers from the Harvard School of Public Health (Grashow et al, 2014) studied the long-term exposure to toxic metals in weld fumes in a group of welders in Massachusetts. The welders provided several toenail samples over a period of time, and the clippings were analyzed.

Some forensics television shows have investigators acquire a  hair sample and test it for poison. This works because many things that get into our bloodstream, including metals, are deposited in our hair and fingernails as they grow.  The researchers chose toenails because they grow more slowly and give a record that covers a longer period of exposure.

welding fumes

So what did they find?

Even among workers who wore respirators, researchers were able to detect lead, manganese, cadmium, nickel, and arsenic. Lead is a well-known health hazard, and you probably don’t need to be told that arsenic isn’t a good thing either. Long-term exposure to manganese is associated with central nervous system problems that can mimic Parkinson’s disease. Cadmium is known to cause cancer, and nickel can cause skin problems and lung irritation.

Respirators are a key part of controlling exposure to welding fumes. These welders, though, were still exposed to enough of these metals that it could be found in their toenails. While it wasn’t within the scope of this research study to determine exactly how workers were exposed, one possibility is that respirators may be worn while welding, but not while doing other work around the shop in places where dust from cutting and welding may have accumulated.

A dust collection system that removes welding fumes and dust from the air completely will prevent  toxic metal particles from accumulating in your work areas. Respirators may prevent inhalation during welding, but if the weld fumes aren’t being removed from the air, workers can still be exposed to it. A system that keeps the air clean for your entire facility doesn’t just protect workers while they’re wearing respirators. It protects all of your workers, all of the time.

 

Grashow, R. et al (2014). Toenail metal concentration as a biomarker of occupational welding fume exposure. Journal of Occupational and Environmental Hygiene, 11, 397-405.

The Value of Dust Collection Management

Dust collection management is one of the main investments that those in the timber industry must face in the near future.   In fact, Timber Processing Magazine (www.timberprocessing.com), which conducts research on industry production, supply, and investments, notes that many facilities will need to plan for additional equipment needs above and beyond those they have already planned for.

Areas where facilities may need to plan for investments include:

Dust collection management

Complete BRF System Installation

  • Loading equipment
  • Drying kilns
  • Planer mill sorting and packaging
  • Forklifts
  • Conveyers
  • Dust control

Because of the extremely combustible nature of wood production dust and OSHA’s increasingly strict regulations on combustible dust collection management, dust collection equipment is one of several investments that companies in this industry may need to consider.

Modernization of equipment is often essential to streamline production and materials handling. According to the surveys conducted by Timber Processing Magazine, almost 75% of facilities rated their return on investments in 2015 as “good” or “excellent”.

When considering where to put that investment, dust control equipment should definitely be top on the list. Processing more product creates more dust, and nothing can shut your production down faster than a malfunctioning dust collection system or, worse, a fire.

Even if your current dust collection system is handling your dust adequately, equipment such as explosion isolation valves, spark arrestors, and backdraft dampers can be a valuable investment in fire and explosion prevention. Wood processing dust has its own unique demands on dust collection and fire suppression systems, and an experienced systems engineer should be consulted to make sure equipment is optimized for your particular application.

Good news for the timber industry is also good news for manufacturers who produce equipment for this industry. This recent report makes it clear that this industry is alive and well, and that companies are likely to see long-term benefits from investments they make in new equipment.

Aftermarket Customer Service Matters

We hear it every day from customers.  Aftermarket customer service from other companies that sell replacement filters is not always a pleasant experience.   These customers come to us because they’re tired of automated phone menu systems, messages that never get returned, and questions that never get answered. If you’re ready for a better filter purchasing experience, Imperial Systems is the logical choice.

“Your customer doesn’t care how much you know until they know how much you care”. – Damon Richards

This could not be more true of our philosophy.  While you know that Imperial Systems custom-designs and manufactures the best dust collectors in the industry, you should also know that we  have a dedicated aftermarket team ready to assist you. Whether you need spark traps, replacement airlock parts, or new DeltaMAXXTM filters, our team will be with you all the way.  From finding the right part to making sure you’re satisfied with your order.

When you work with Imperial Systems, you’re not just a number, you are a priority! One of our aftermarket customer service professionals will manage your account, and will make sure you always receive a prompt, personal, and helpful response to all of your needs. You’ll always know exactly who to call.  You won’t have to explain what you need every time you call us because we already know who you are!

Here are a just a few of our aftermarket professionals committed to providing you with the best service in the industry.

Aftermarket customer service team

Rebecca, Justin, and Patrick

When you call us for your filters or other aftermarket needs, one of us will be there, in person, ready to return your calls, answer your questions, and solve your problems with the kind of personal attention your business deserves. You treat your customers like they matter. Come and work with the aftermarket sales team who treats you like YOU matter.  Call today at 800-918-3013!

 

Case Study: Duct and Fitting Design at the Longaberger Company Facility

Large basket and Home Furnishing Company chooses Imperial Systems

Due to the decline in economy value, the Longaberger Company had just sold one of their bigger buildings to move across the industrial park into one of their smaller facilities.

 The Duct and fitting on the building was roughly ten years old, so it was time for a modification project. The goal was to find a company with expert engineers that could help with cutting cost, efficiency, and manufacturing the desired ductwork.

After hearing about what Imperial Systems had to offer from the staff at an Air Systems plant in Indiana, the Longaberger Company decided to reach out to Jeremiah Wann (president/CEO) at Imperial Systems to discuss the upcoming duct and fitting installation.

The Longaberger Company decided to go with Imperial Systems because of cost and what the company had to offer as far as design, layout, and their expert knowledge as a complete systems manufacturer.

Why Choose DeltaMAXX Nanofiber Dust Collector Cartridge Filters ?

At Imperial Systems, Inc. we know that checking up on your dust collector’s performance can often be a lost thought, unless your dust collector is consistently giving you fits. In order to make your life easier, we have manufactured the most cost effective, dust collector cartridge filter in the industrial dust collection industry. Our DeltaMAXX NanoFiber Dust Collector Cartridge Filters are designed to over-achieve while reaching maximum performance inside of your dust collector. Our goal is to sell you the best dust collector cartridge filter we can at a fair price. 

Here are 10 reasons why DeltaMAXX Dust Collector Cartridge Filters will work for you:

1. With 99%+ efficiency on 0.3-0.4 micron particulate our cartridge filters provide maximum filtration resulting in the best performance in cartridge-style dust collectors

2. Compared to our competition, our nano-fibers are 50% smaller resulting in an industry high MERV 15 efficiency rating.

DeltaMAXX dust collector cartridge filters

 

3. Our surface-loading technology with nano-size inter fiber pores allow caked dust to easily pulse off of the surface layer keeping the filter media clean.

4. Less pulse cleaning + Less Filter Stress = Longer filter life

5. Longer filter life means fewer filter changes and less downtime – saving you money!

6. Reduced Outlet emissions = Cleaner Air

7. Less compressed air consumption for pulse jet dust collectors.

8. Flexibility – nanofiber can be applied on all kinds of dust collector filter media including cellulose, spunbond, and synthetic media resulting in improved cartridge filter media.

9. DeltaMAXX Replacement Dust Collector Cartridge Filters are made for all brands of industrial dust collectors.

10. We carry a large stock of our manufactured DeltaMAXX Dust Collector Cartridge Filters resulting in timely shipping to your establishment.

 

Check out our DeltaMAXX Dust Collector Cartridge Filter webpage as well as our Case Studies and Testimonials regarding our cartridge collector filters.