by Imperial Systems | Aug 5, 2015 | Common Industrial Dust Collection System Problems
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.
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)
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:
Hazardous 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.
A 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
If 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
This 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. 
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!
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by Imperial Systems | Jul 31, 2015 | Common Industrial Dust Collection System Problems
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?
At 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:
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- 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
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by Imperial Systems | Apr 30, 2015 | Common Industrial Dust Collection System Problems
The metalworking industry can be a risky and sometimes fatal, business. Let Imperial Systems pave your way to safety.
In 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.
- Dust particles must be in heavy concentrations
- 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
- There is presence of combustible dust that may be released into the air
- Materials are processed into tiny particles
- Areas that dust can accumulate for a long period of time are present
- Activities that the consumption or production of combustible dust is present
- 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
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by Imperial Systems | Mar 27, 2015 | Common Industrial Dust Collection System Problems, Dust Collection Filters
The importance of dust collection can’t be underestimated when your life is in danger.
Dust collection has become an important issue in many industries that must produce raw materials, such as metalworking or wood pellet manufacturing. The importance of dust collection cannot be understated, especially since employers must now abide by OSHA standards for dust procedures.
What are the dangers of dust? Dust accumulates in the produced material during operations and because of its large quantity and combustible properties, may become a fuel—leading to accidental fires and explosions. The combustible nature of dust has made it hazardous in work environments as we have seen through several unfortunate incidents in factories around the US documented over the past 10 years. OSHA defines combustible dusts as “fine particles that present an explosion hazard when suspended in air in certain conditions.”
Dust that accumulates at wood pellet plants during the production process can end up being a fuel source itself, fueling unwanted fires or explosions. Effective dust management must be an integral aspect of all manufacturing plants as a continual prevention process. “Essentially we are taking a woody product, reducing its particle size and drying it into its most combustible form, and then densifying it afterward,” says Shawn Bells, general manager with Pacific BioEnergy. “So with regard to what we do, we’re probably doing the exact opposite of what you are supposed to be doing—we are creating a fuel—so then we have to deal with it.”
Producers understand now that their operations must be governed strictly by dust control and management in order to abide by OSHA. President of American Wood Fibers Stephen Faeher explains that this increased awareness became prominent around 10 years ago. “OSHA became focused on dust control and management. That’s, I think, when it heightened everyone’s awareness.”
What is OSHA?
The Occupational Safety and Health Administration governs employment safety by providing employers with hazard-specific safety and health standards. The Occupational Safety and Health Act requires that employers comply with health standards given by OSHA or a state-approved plan. The General Duty Clause of the Act (Section 5 (a) (1)) requires that employers maintain a work environment free from recognized hazards which could cause serious harm or death.
What Causes Dust Explosions?
The importance of dust collection as a preventative measure is seen in the FIRE TRIANGLE: the elements needed for a fire. In our case, dust comprises the “fuel”:
- Combustible dust (fuel)
- Ignition source (heat)
- Oxygen in air (oxidizer)
In addition, a dust explosion is more likely when the dust cloud is ignited within a confined area. When that dust is further dispersed, this can cause an even more severe second explosion. This may occur after the first explosion shakes fugitive dust into other places. If you have had the warning of a first explosion, be sure to watch out. A second explosion can be more dangerous and create more widespread damage than the first.
The Employer’s Responsibility for Worker Safety
One of the most effective ways to prevent explosions is to train employees to recognize the warning signs of combustion. The importance of training the people closest to the hazard cannot be underestimated, as they can be instrumental in sighting unsafe conditions and calling on management.
Though the OSHA regulations necessitate that certain employees be trained, it is recommended that employers issue basic education on the importance of dust collection and combustion prevention procedures. Such education should include information on plant programs on dust management and ignition source controls. The training should be required in these circumstances:
- Pre-assignment training
- Periodic refreshers-i.e. every 6 month re-licensure for work in these environments
- Re-assignment training-i.e. any time work location changes, employees should receive information correspondent to that area
Training should include a practical as well as a lecture aspect. All lectures should be followed or accompanied by demonstrations of the procedures, and as much as possible, employees should be asked to repeat the procedure for the practical element. Repeating the procedure under supervision with feedback given for each practice re-enforces the most important tasks and ensures that employees have absorbed the detail given by the lectures.
It should also be noted that employers holding hazardous chemicals, which includes combustible dusts, must comply with the Hazard Communication standard, 29 CFR 1910.1200.. Included in this regulation is the law that all containers of hazardous chemicals must have labels on them, and the requirement to provide employee training.
Case Study of Dust Fire and Explosion: Massachusetts (3 killed, 9 injured)
In 1999 there was a deadly fire explosion in a foundry in Massachusetts which killed 3 and injured 9 employees. The Occupational Safety Health Administration (OSHA), supported by state and local officials, conducted an investigation of the happening to determine its causes.
It was discovered that the fire commenced within a shell molding machine and continued into ventilation systems, fueled by deposits of phenol formaldehyde resin dust. The small fire initiated within the ductwork and dislodged dust sitting on outside of the ducts. This caused a dust cloud to formulate, causing a second explosion (as explained above). The investigation concluded that the following were necessary to prevent such explosions in the future:
- Housekeeping to manage dust accumulation
- Ventilation system design
- Oven maintenance
- Equipment of safety devices
This case study shows the necessity for laws surrounding the proper use and disposal of dust types. Other incidences of dust explosions have still been common since 1999, as most standards of national and international safety bodies have been only recommended. But in 2003 alone, there were three dust explosions that caused 14 deaths. The US Chemical Safety & Hazard Investigation Board launched a study of industrial dust explosions.
From 1980 to 2005 there were 281 dust fires in US businesses, causing 119 deaths that could have been prevented. Clearly, dust accumulation and dispersion is a problem that continues to plague production facilities—confirmed by the fact that since the 2003 investigation, 70 more dust fires have taken place within US businesses.
Where are companies going to ensure that their facilities are safe for the worker? What combination of dust protection products and employee training are being used to guard against fires? How are you seeking to prevent dust explosions from occurring in your facilities?
Professional Dust Collection and Management Services
If what you have read thus far is ringing alarm bells for you, you may need dust and fume collection equipment to guard your employees’ safety and the livelihood of your company assets. Over the past ten years, Imperial Systems has provided manufacturers the most advanced and reliable equipment for prevention of dust-induced explosions.
We manufacture all our materials from our own store in western Pennsylvania, so that we can ensure that you have the most quality product possible. We offer the following products:
- CMAXX Dust Collector System
- DeltaMAXX Cartridge Filters
- CMAXX Laser Fume Extraction System
- Heavy Duty Abort Gates
- Airlocks
- Backdraft Damper
- SCF Dust Collectors
- Diverter Valves
- Spark Arrestor
- Lidegates
- Flex hose
We hope that our research on the importance of dust collection and process maintenance has been helpful to you as you seek to instill the best practices in your company. At Imperial Systems, we want to bring true value to your company’s systems by using our expertise in the industry and our unique, “home-made” products. We thus hope to be a resource to you as you figure out what your needs are and how best to follow OSHA regulations as summarized above.
For now, we leave you with the question: When was the last time you checked your dust collection processes? Are all your boxes checked in the areas of housekeeping (dust accumulation removal), proper ventilation, safety equipment, and oven maintenance? How often are your employees trained, and are they receiving all the information they need to prevent dust explosions in your manufacturing plant? Don’t hesitate to call us with any questions.
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