Foundries are integral to manufacturing and industrial processes, producing metal castings by melting and pouring metal into molds. However, the very processes that make foundries indispensable also generate significant amounts of dust and fumes. Consequently, without proper dust collection systems in place, this dust can pose serious health risks, environmental hazards, and operational inefficiencies.
Health and Safety Concerns Over Foundry Dust
Above all, the primary reason for implementing proper dust collection systems in foundries is to protect the health and safety of workers. Foundries typically produce various dust types, including silica, metal particulates, and chemical residues. As a result of inhaling these particles, severe respiratory issues, including chronic obstructive pulmonary disease (COPD), silicosis, and other occupational illnesses can develop. Effective dust collection systems capture airborne particles before they can be inhaled, ensuring a healthier working environment.
Furthermore, reducing dust levels in the air helps prevent workplace accidents. For instance, dust accumulation can create slippery surfaces and reduce visibility, leading to injuries. By maintaining clean air and surfaces, dust collection systems contribute to overall workplace safety.
Regulatory Compliance
Foundries are subject to stringent environmental and occupational health regulations. Agencies such as the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) in the United States have set limits on permissible exposure levels for various dust and fume contaminants. Consequently, non-compliance with these regulations can result in hefty fines, legal actions, and even operational shutdowns.
Proper dust collection systems ensure that foundries remain compliant with these regulations by effectively capturing and controlling dust emissions. This not only avoids legal repercussions but also demonstrates a commitment to responsible environmental and occupational practices. Working with a dust collection partner familiar with these regulations will ensure a properly designed system.
Protecting Equipment and Product Quality
Dust can be detrimental to the machinery and equipment used in foundries. Accumulated dust can lead to mechanical failures, increased wear and tear, and the need for more frequent maintenance. By implementing an efficient dust collection system, foundries can keep their shop clean and protect their equipment from damage, thereby reducing downtime and maintenance costs.
Moreover, dust can contaminate the products being manufactured, leading to defects and reduced quality. Ensuring a clean environment through proper dust collection helps maintain high product standards and reduces the risk of costly rework or scrap.
Environmental Impact of Foundry Dust and Fumes
The environmental impact of foundry operations is a growing concern, particularly with increased awareness of air pollution and its effects. Dust and fumes released into the atmosphere can contribute to environmental degradation, affecting air quality and harming local ecosystems. Implementing dust collection systems minimizes the release of harmful particulates into the environment, thereby reducing the foundry’s ecological footprint.
Effective dust collection also supports sustainability initiatives by facilitating the recycling and proper disposal of collected dust and particulates. This aligns with broader industry trends toward sustainable and environmentally friendly manufacturing practices.
Operational Efficiency
Efficient dust collection systems can enhance the overall operational efficiency of foundries. By maintaining a clean working environment, these systems reduce the likelihood of equipment malfunctions and extend the lifespan of machinery. This translates to smoother operations, fewer interruptions, and lower maintenance costs.
Additionally, a cleaner workplace improves staff morale and productivity. Employees are more likely to perform better in a safe, clean, and healthy environment. This can lead to improved operational output and efficiency.
The necessity of proper dust collection in foundries cannot be overstated. From protecting worker health and safety to ensuring regulatory compliance, maintaining product quality, minimizing environmental impact, and enhancing operational efficiency, effective dust collection systems are indispensable. Foundries must prioritize the implementation and maintenance of these systems to safeguard their operations, workforce, and the environment. Investing in proper dust collection is not just a regulatory requirement but a critical component of responsible and efficient foundry management.
Leading a company that stands out in the field of thermal plastics compounding, Jim LeGacy, the President of Orion Performance Compounds in Lugoff, South Carolina, emphasizes excellence and innovation in their operations. At Orion, the meticulous process of transforming raw polymers into high-performance materials for a variety of industries is executed with precision and a relentless focus on cleanliness and safety. From military and aerospace applications to electrical and healthcare products, Orion’s reach extends far and wide, serving some of the most demanding sectors.
High Standards in a Demanding Industry
Plastics compounding is a complex field that involves working with different types of polymers. They can include anything from polypropylene to high-temperature resins. Also, different polymers are needed to create materials that meet specific performance criteria. Customers of Orion Performance Compounds rely on these materials to produce their plastic products when using injection molding techniques. Because of the sensitive nature of some industries they serve, the quality and cleanliness of Orion’s manufacturing environment are non-negotiable.
Commitment to Safety and Cleanliness
At Orion, maintaining a pristine facility is more than a matter of aesthetics; it’s a core principle that underscores their commitment to safety and quality. “Safety and cleanliness are at the top of our list of core principles,” says Jim LeGacy. This dedication is certainly evident to anyone who visits their plant. “Yesterday we had a potential customer come through. They got fifty feet outside the door to the plant and they said that it was the cleanest compounding operation they’d seen,” recounts Jim.
The Role of Effective Dust Collection in Plastics Compounding
In order to achieve this level of cleanliness, Orion partnered with Atlantic Dust Collection out of Kernersville, North Carolina, to install a state-of-the-art CMAXX Dust & Fume Collector. This system plays a crucial role in keeping the facility free from airborne contaminants that can stain and discolor materials, ensuring a safe and clean working environment.
Phil Bramblett, the site manager at Orion, underscores the importance of a robust dust collection system, especially when dealing with dry materials in powder, granular, and pellet forms. “Having a good dust collection system is vital to the operation of the plant,” Phil asserts. The effectiveness of the CMAXX unit in maintaining air quality is another testament to Orion’s commitment to operational excellence.
Why the CMAXX Stands Out
Phil shares that while competitors also produce acceptable dust collection systems, they often come with engineering issues. “The unit that we have now, one of the reasons that we chose that, was to try to alleviate some of those problems.” The CMAXX unit, described by Phil as “the Cadillac of dust collection units,” was chosen above all for its superior design and the quality of its construction. The ease of filter removal is another feature that sets it apart to Orion, making maintenance simpler and more efficient.
A Testament to Quality Plastics Compounding
The partnership between Orion Performance Compounds and Atlantic Dust Collection exemplifies the importance of selecting the right equipment and collaborators in maintaining high standards of cleanliness and safety. “Atlantic was great,” Phil notes, appreciating their customer service and attention to detail. This collaboration not only ensures a cleaner facility but also positions Orion ahead of its competition by providing a safer and more appealing environment for both employees and clients.
Orion Performance Compounds’ commitment to cleanliness and safety, reinforced by their partnership with Atlantic Dust Collection and the installation of the CMAXX Dust & Fume Collector, highlights the company’s dedication to excellence. By maintaining a clean and efficient facility, Orion not only meets the rigorous standards of its diverse clientele but also sets a benchmark in the thermal plastics compounding industry. The success story of Orion Performance Compounds serves as an inspiration, showcasing how the right combination of technology, partnership, and core values can drive a company to new heights.
In the world of industrial dust collection, maintaining high efficiency and prolonged baghouse filter bag life is crucial. One effective method to achieve this is by applying a pre-coat to the filter bags with specific materials before use. Pre-coating involves applying a material layer to the filter bag media. This creates a base cake that enhances filtration efficiency and extends the filter’s operational life.
The Importance of Pre-Coating
New filter felt media is inherently porous, allowing fine particulate matter, especially those ½ micron and smaller, to pass through. Pre-coating forms an initial layer on the filter media. This significantly increases its efficiency by capturing fine particles and reduces the chances of premature clogging.
Various pre-coat materials are available, including diatomaceous earth, lime, perlite, cellulose, and activated carbon. But the choice of material depends on the specific filtration requirements and the type of filtered particulate. Consulting the filter manufacturer can provide valuable guidance on selecting the most suitable pre-coat material for your particular application.
Preparing and Mixing Pre-Coat Materials
Some pre-coat materials require mixing multiple ingredients to achieve uniform consistency. Ensuring thorough mixing before application is vital for achieving even distribution and optimal filter performance.
Preparing the Baghouse for Pre-Coat Application
Before applying pre-coat to the filters in a baghouse dust collector, certain preparations are necessary:
Remove all previous dust from the baghouse hopper and deactivate the hopper dust removal equipment, such as airlocks.
Deactivate and lockout the baghouse cleaning system to prevent filter cleaning during the pre-coat period.
Pre-Coat Application Methods for Different Baghouse Systems
Negative Pressure Systems: In negative pressure baghouse systems, where the baghouse is under suction, inject the pre-coat through ports or inspection doors in the duct or directly into the dust collector inlet or hopper.
Positive Pressure Systems: For positive pressure systems, where the fan blows into the dust collector, inject the pre-coat into the system ductwork on the suction side of the fan.
Calculating and Applying Pre-Coat
A good rule of thumb is to use one pound of pre-coat for every 20 square feet of baghouse filter media. Operate the system at 50% of the design airflow to the baghouse. This results in an inlet duct velocity of approximately 2000 FPM. Avoid dropping the velocity below this threshold. Then use a pre-coat feed rate of 1/3 pound per minute per 1000 ACFM of reduced airflow. For instance, for a 25,000 ACFM reduced airflow system, the feed rate would be 7.5 lbs./minute.
Inspecting and Ensuring Adequate Pre-Coat Coverage
Isolate each filter compartment and inspect the filter bags to ensure an adequate pre-coat cake, approximately 1/16 inch thick. Then check the collector hopper to confirm that there is not a significant amount of pre-coat dropout.
Once the pre-coating process is complete, increase the air volume to the normal dust collector design flow level. Then turn on the dust removal equipment (airlock). However, do not reactivate the filter bag cleaning cycle until a differential pressure of 3 to 4 inches SPWG is measured across the bags. This step ensures that a seasoned cake of pre-coat has formed on the filter bags before initiating the initial cleaning cycle.
Pre-coating filter bags is a proven method to enhance the efficiency and longevity of dust collection systems. By selecting the right pre-coat material, properly preparing and applying it, and carefully monitoring the process, facilities can ensure their dust collectors operate at optimal performance levels. This not only improves air quality but also extends the life of the filters, contributing to overall operational efficiency.
Pre-coating pleated cartridge media is a standard practice that enhances the performance and lifespan of dust collection systems. This process involves applying a layer of pre-coat material onto the filters to improve their filtration efficiency and protect them from premature clogging and wear.
Types of Pre-Coat Materials
Several types of pre-coat materials are available. Examples include diatomaceous earth, lime, perlite, cellulose, and activated carbon. The choice of pre-coat material depends on the specific filtration requirements and the nature of the filtered particulates. Consulting the filter manufacturer can provide valuable insights into selecting the most appropriate pre-coat material for your application.
Mixing Pre-Coat Materials
Some pre-coat materials may require mixing multiple ingredients. It is crucial to ensure that all components are thoroughly mixed to achieve a uniform consistency before applying the pre-coat to the filters. As a result, this uniformity ensures consistent coverage and optimal performance of the filters.
Application Method
Above all, the simplest method to apply pre-coat to cartridge filters is by installing the filters in the dust collector and activating the system fan. This setup draws the pre-coat material into the collector, allowing it to evenly coat the filter media. Before beginning this process, inspect all pleated cartridge filter elements for defects or damage and clean off any debris. Achieve best results when pre-coating newly installed filters.
Adjusting the Cleaning System
When pre-coating clean cartridge filters for the first time, it is recommended to turn off the pulse cleaning system or set it to “pulse-on-demand” mode. This adjustment ensures that all filters receive an even pre-coat layer before the collector cleaning system begins its pulsing cycle. This helps in achieving a uniform pre-coat distribution, enhancing filter efficiency.
Monitoring Differential Pressure
While applying the pre-coat, it is essential to monitor the filter differential pressure to ensure proper filter efficiency and prevent excessive pressure buildup. Typically, the pressure drop during pre-coating should remain minimal, indicating that the pre-coat is evenly distributed and has not excessively clogged the filter media pores. A slight increase in pressure drop is normal as the pre-coat layer forms, but it should stay within acceptable limits.
Methods of Pre-Coat Application to Cartridge Filters
Apply pre-coat to cartridge filters mounted in the collector using various methods. Use an injection system to introduce metered amounts of pre-coat into the dust collector while it is running. Another method is to apply pre-coat manually by pouring the material directly into an open port on the dust collector inlet or through the flange opening on the dirty air inlet.
Pre-Coat Ratio and Layer Thickness
The ratio of pre-coat to filter area varies depending on filtration requirements and the type of pre-coat material used. A good rule of thumb is to apply a layer of pre-coat between 1/16 to 1/8 inch thick over the entire surface area of the cartridge filters. Allow sufficient time for the pre-coat layer to form and settle onto the cartridge surface, following the manufacturer’s recommendations for the specific pre-coat materials used.
Maintenance and Inspection
Maintaining the filtration system according to the manufacturer’s recommendations is crucial for optimal performance. This includes periodic inspections, cleaning, and replacement of cartridges as needed. Further, regular maintenance ensures that the pre-coat layer remains effective and that the filters continue to operate efficiently.
Calculating Pre-Coat Volume for Cartridge Filters
Calculate the total volume of pre-coat required using the following formula:
Total surface area of all filter media x Desired thickness of pre-coat layer
By following these guidelines, you can maximize the efficiency and longevity of your pleated cartridge filters, ensuring a cleaner and safer working environment.
By incorporating pre-coating into your dust collection system maintenance routine, you can significantly enhance filter performance and extend their service life. Thus, proper selection, application, and maintenance of pre-coat materials are essential for achieving optimal results and maintaining a safe, clean workplace.
In Gardena, California, Steve Bunyard leads a transformative initiative called ReIGNITE Hope. The name itself reflects a powerful mission: to reignite hope in individuals who have lost it. Through welding education, ReIGNITE Hope offers a lifeline to many who society marginalizes, providing them with the skills and confidence to forge a new path in life.
A Vision Born on Skid Row
ReIGNITE Hope’s roots trace back to Skid Row, where Steve Bunyard was engaged in meal service and clothing distribution as part of his church’s outreach program. But over time, Steve noticed a disheartening trend: the same faces reappearing in the food and clothing lines, ond those lines growing longer. It became clear that while the immediate needs of food and clothing were being met, the deeper issue of sustainable change remained unaddressed. Consequently, Steve found himself questioning how this cycle of dependency could be broken.
Driven by a desire to find a solution, Steve turned to prayer. As a result, the answer came in an unexpected form: welding education. The initiative began humbly with five homeless men at the Fred Jordan Mission. Soon, five men’s lives would radically change, finding purpose and dignity through learning a skilled trade. Word spread quickly, and soon there was a surge of interest in the program.
Growing Impact
The program, which is free of charge, has a clear mission: to lead individuals vocationally toward a career and spiritually toward Christ. From its modest beginnings with five participants, ReIGNITE Hope has grown exponentially, training hundreds of students annually across multiple locations. The impact of this initiative certainly extends far beyond the classroom, as graduates find real career opportunities that provide stability and hope for a better future.
ReIGNITE Hope Offers a Path to Career and Faith
ReIGNITE Hope’s dual mission is unique, focusing not only on vocational training but also on spiritual growth. This approach addresses both the practical and emotional needs of participants, helping them rebuild their lives on solid foundations. Graduates of the program gain valuable welding skills, opening doors to various career opportunities in industries that are constantly in need of skilled workers. This dual focus has proven to be a powerful combination, enabling individuals to achieve self-sufficiency and regain their sense of purpose.
Commitment to Safety
From the outset, safety has been a paramount concern for Steve and his team. Welding, while a valuable skill, comes with its own set of hazards, particularly the fumes generated during the process. Steve emphasized the importance of a safe learning environment, stating, “We want the air to be healthy here for them to breathe. Welding creates fumes. There is no getting around that.”
Recognizing the need for improvement over their previous ventilation system, Steve was elated when Imperial Systems stepped in to help. “I was absolutely amazed that Imperial wanted to donate a system to us,” Steve recalls. Imperial Systems, a leader in industrial dust collection solutions, donated a Shadow unit to ReIGNITE Hope’s second mobile training 18-wheeler. This state-of-the-art system significantly improved air quality and ensured a safer environment for students and instructors alike.
Grateful Partnership with Imperial Systems
The collaboration with Imperial Systems marked a turning point for ReIGNITE Hope. The advanced dust collection system not only enhanced safety but also demonstrated the power of community support and corporate responsibility. Steve expressed his gratitude, saying, “I am stunned by how well that thing works. I praise God for Imperial and their heart to help with this.”
The donation of the Shadow unit underscored Imperial Systems’ commitment to giving back and supporting initiatives that make a tangible difference in people’s lives. This partnership enables ReIGNITE Hope to continue its mission with even greater confidence, including the knowledge of the protection of the health and safety of its participants.
The Ongoing Journey
Steve Bunyard’s journey with ReIGNITE Hope is a beacon of possible achievement when one refuses to accept the status quo and dares to envision a better future. The impact of this program extends far beyond technical skills, touching the very core of human dignity and potential. Each success story that emerges from ReIGNITE Hope is a testament to the power of faith, education, and the unyielding belief in second chances.
As the organization moves forward, the support from partners like Imperial Systems will continue to play a critical role. Their contribution not only enhanced the safety and efficiency of the training environment but also validated the importance of ReIGNITE Hope’s mission. This partnership exemplifies how collaborative efforts between organizations and communities can certainly drive meaningful, long-term change.
In conclusion, ReIGNITE Hope stands as a powerful example of achievable accomplishment when compassion meets action. Specifically, by providing a pathway to vocational success and spiritual growth, the program offers a renewed sense of purpose and hope to those who need it most. So, Steve Bunyard’s vision, supported by the dedication of his team and the generosity of partners like Imperial Systems, continues to light the way for countless individuals seeking a fresh start and a brighter future.
Protecting Equipment and Product Quality 
