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.
Cresswood Shredding Machinery, an Illinois-based company, has been innovating in manufacturing for over 40 years. Their journey began in 1979, crafting residential stoves and fireplace inserts. Over time, they evolved into the realm of industrial furnaces, and then automated boiler systems.
Initially, they utilized German grinders for wood, paper, and plastic to grind material for boiler stokers. After a while, they were not satisfied with the quality of the imported product. So, Cresswood decided to design and build their own grinders – a venture they have successfully undertaken for the past 35 years.
This pivotal shift, however, presented a new challenge: dust and smoke. That is because a crucial aspect of their shredder manufacturing process involved using flex core welding wire, which generated a significant amount of smoke. As Jack Cress, CEO of Cresswood Shredding Machinery, explains, “One of the critical aspects of a weld shop is smoke.”
Cresswood had tried various solutions to combat the welding smoke. They experimented with fume extraction systems attached directly to the welding guns and employed fans to try to pull the smoke out of the building entirely. Unfortunately, none of these methods proved truly effective.
A Breath of Fresh Air: The Imperial Systems Solution
Employee retention is a significant concern across many industries, and Cresswood recognized the importance of fostering a pleasant work environment. Jack explains, “For the last 20 years, it’s been a serious problem to create an environment that employees want to work in.” Clean air was certainly a key piece of that puzzle.
Jeremiah Wann at Imperial Systems listened to Jack’s concerns and proposed a solution: the Shadow Compact Fume Extractor. This innovative system proved to be a significant change for Cresswood Shredding Machinery. Shop employees finally had a smoke-free environment to work in.
“It’s very difficult to get employees and employee retention, and part of that is creating an environment where they want to work,” emphasizes Jack. The impact of the Imperial Systems solution goes beyond just improved air quality; it contributes to a happier, healthier workforce.
Cresswood Shredding Machinery’s story exemplifies the power of innovative solutions. By partnering with a company like Imperial Systems, they were able to address a longstanding challenge and create a more positive work environment for their employees. This not only benefits worker well-being but also contributes to a more productive and successful company overall.
For any automotive outfitter, a clean and healthy work environment is paramount. But for this North Carolina-based company, achieving that goal presented a unique challenge – dust. Their fiberglass operation generated significant airborne particles, impacting product quality and employee well-being. Further, as they transitioned into a new building, they knew they needed a robust dust collection system designed for their specific needs.
This North Carolina automotive outfitter was expanding their operation into a new building, and adding processes that required dust collection. However, their existing dust collection system, designed for their previous space, simply wouldn’t suffice. Their high-output machines, including saws and multi-head sanders, produced more dust than the old system could handle
“It simply would have overwhelmed our system and dust would have been everywhere,” a company representative recalls. Not only would this have impacted the quality of their work, but it also posed health and safety concerns for their employees.
Finding the Perfect Fit: Automotive Outfitter Searches for a Tailored Dust Collection Solution
Knowing they needed a tailored solution, the company embarked on a search for a dust collection partner. They prioritized finding a company that could not only deliver a powerful system but also a system that would work with their specific needs. This application needed a source capture system that would collect debris directly at the point of generation.
After careful consideration, they chose to work with Imperial Systems. “We felt that Imperial delivered the most value, as well as gave us the highest level of confidence that they were going to deliver a turnkey solution,” their representative explained.
Imperial Systems rose to the challenge, designing and installing a CMAXX Dust and Fume Collector specifically engineered for the automotive outfitter’s unique needs. The new system boasts a much higher capture rate, effectively preventing dust from spreading throughout the facility.
Imperial Systems: Committed to Excellence
This has yielded significant benefits for both the company and its employees. The increased material removal rate translates to improved efficiency and productivity. More importantly, employees experience great air quality within the shop. The CMAXX has been able to keep the new building clean.
The company is particularly impressed with Imperial Systems’ dedication to service. “We’re definitely impressed with the team,” they say. The system was installed in the middle of July on a roof in North Carolina. The team worked sun up to sun down daily to ensure the unit was installed on time.
At the time of the interview, the 96 filters within the dust collector haven’t required replacement. A representative reports that the differential pressure is still very low, at almost new conditions. “We have not had to change our filters in a year and a half,” they said. This not only saves them money but also minimizes downtime for maintenance.
The new dust collection system from Imperial Systems has been a game-changer for this North Carolina automotive outfitter. They are extracting more dust than ever, resulting in a cleaner, healthier work environment, improved product quality, and increased efficiency. This success story serves as a testament to the power of partnering with a company that understands the specific needs of its clients and delivers exceptional service every step of the way.
Cronimet Specialty Metals, a metals recycling facility, recently faced a unique challenge in its operations. The nature of their work with specialized materials – stainless steel, tungsten, and cobalt – necessitates the use of powdered catalysts. While essential to the process, these catalysts generated airborne dust. Additionally, losing this valuable material represented a missed opportunity for resource recovery.
Balancing Air Quality and Resource Recovery in Recycling
Other dust collection systems, while effective for general particulate control, wouldn’t suffice for Cronimet’s specific recycling needs. They required a solution that not only minimized dust but also facilitated the crucial reclamation of the catalyst material for continued use.
Custom-Designed Solution: Imperial Meets the Challenge
Partnering with Imperial Systems, Cronimet was able to implement a customized dust collection system designed to address their unique challenges. Imperial Systems’ team of experts understood the critical nature of both air quality control and resource recovery. Their solution effectively minimized airborne particulates within the facility while simultaneously enabling the efficient reclamation of the dust for further utilization in the recycling process.
Beyond Clean Air: Recovering Revenue and Setting a New Standard
The positive impact of the implemented system extends beyond air quality benefits. “We’re recovering lost revenue when it was just going into the air, onto the walls, and onto the floors,” said Robert Taylor, who works in maintenance at Cronimet Specialty Metals. “It worked better than our expectations.”
The collaboration between Cronimet Specialty Metals and Imperial Systems goes beyond the technical aspects of the dust collection system. Taylor emphasizes the exceptional level of customer service provided by the Imperial Systems team. “Everyone at Imperial Systems just goes out of their way to answer all the questions and make sure we got everything we wanted, and we did,” said Taylor in a testament to Imperial Systems’ commitment to client satisfaction.
By leveraging Imperial Systems’ expertise in dust collection technology, Cronimet Specialty Metals is not only achieving a more sustainable recycling process but also establishing a new standard for responsible and efficient metal resource recovery. When it’s time to purchase additional dust collectors, Taylor made it clear which manufacturer the company would be going with. “We’ve used other manufacturers. I won’t use their name, but there’s a big one that’s blue. I think the quality, comparing this system to competitors, is so much better,” said Taylor.
Calculating and Applying Pre-Coat 
