Why You Need This Guide
When your production line evolves, so should your air filtration system.
Common upgrade scenarios include:
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Production Expansion or Process Upgrade: New suction points or extended duct networks in metalworking, electronics/semiconductors, food processing, chemical and pharmaceutical industries, and woodworking.
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Dust Becoming Finer, Stickier, or More Hazardous: Examples include graphite, carbon powder, flour, sugar dust, color pigments, plastic powder, aluminum and magnesium dust, pharmaceutical dust, or vapor mixtures.
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Aging Dust Collection Systems: Common issues include insufficient airflow, energy waste, rising pressure drop (ΔP), clogged filters, high noise levels, and noncompliance with occupational or environmental standards.
1. Key Terms Explained in 3 Minutes
Airflow (CMM): The total air volume handled per minute. Determine total airflow by summing individual suction demands from each workstation.
Static Pressure (Pa / mmH₂O / mmAq): The resistance your system must overcome. It determines whether your blower has enough pressure head to move air effectively.
A/C Ratio (Air-to-Cloth, m/min): Indicates filter surface velocity. A lower ratio means slower clogging and more stable ΔP, though it may require a larger housing.
ΔP (Pressure Drop): The pressure difference between the filter’s inlet and outlet, increasing with dust load and filter aging.
HEPA (Secondary Filtration): Grades H13/H14 for fine dust or cleanroom applications.
Combustible Dust / Explosion-Proof Design: For materials such as aluminum, magnesium, sugar, wood, or plastic powder, evaluate Kst / MIE parameters and explosion mitigation options (venting, suppression, isolation, grounding).
L/G Ratio (Wet Scrubber): Gas-to-liquid ratio that affects collection efficiency and energy consumption—essential in wet-type dust collectors.
2. Three-Step Selection Method (with Sample Calculation)
Step 1|Identify Dust Sources and Objectives
List suction points such as grinders, polishing stations, weighing booths, loading/unloading points, and mixing areas.
Evaluate:
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Dust properties: particle size, concentration, stickiness, moisture/oil content, combustibility, conductivity, temperature, and corrosivity.
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Site conditions: noise limits, available space, power supply, indoor/outdoor setup, HEPA requirements, or night operation.
Step 2|Estimate Total Airflow (CMM)
Typical reference airflow per suction point:
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Small sanding/weighing booth: 2–8 CMM/point
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Grinding / cutting: 8–20 CMM/point
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Powder feeding / weighing station: 12–25 CMM/point
Then apply simultaneous use ratio (diversity factor) × total suction points + 10–20% future margin.
Example:
4 weighing hoods × 8 CMM + 2 feeding stations × 18 CMM = 68 CMM.
Simultaneous use factor 0.75 → 68 × 0.75 = 51 CMM.
Add 20% margin → ≈ 61 CMM total requirement.
Step 3|Estimate Static Pressure (Pa / mmAq)
Include:
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Friction losses: based on duct length, diameter, velocity, and material.
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Local losses: elbows, tees, dampers, hoods, filter housing, etc.
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Reference:
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Duct velocity: 18–22 m/s for metal dust; 14–18 m/s for general dust.
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Filter module pressure drop: 500–900 Pa (new), 1000–1500 Pa (steady).
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HEPA module: several hundred to 1000+ Pa depending on size and flow.
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3. Choosing the Right Dust Collector Type
Type |
Application |
Advantages |
Limitations |
Recommended For |
Cartridge Dust Collector |
Fine or heavy dust load |
Compact, stable ΔP, pulse-jet cleaning |
Sticky/oily dust may clog; add pre-separator |
Fine powder (PTFE/Nano membrane) |
Baghouse Dust Collector |
High volume, large dust mass |
Handles heavy load, easy maintenance |
Larger footprint, less effective for fine dust |
Well-designed pulse cleaning |
Cyclone + Filter Combo |
Fibrous or coarse dust |
Reduces filter load, prevents clogging |
Adds resistance and equipment cost |
Fibrous or mixed dust |
Wet (Water Wash) Collector |
Spark/explosive dust |
Fire/explosion suppression |
Needs water management, corrosion control |
Aluminum/magnesium powder |
Electrostatic Precipitator (ESP) |
Fume and smoke |
High fine-particle efficiency |
Sensitive to humidity and safety rules |
Special processes only |
4. Selecting the Right Filter Media
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PTFE / Nano Membrane (MERV-16): Best for fine dust; low ΔP and easy cleaning.
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Anti-static Filter: Required for combustible or electrostatic dust (e.g., sugar, plastic).
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Oil/Water Repellent: For oily or moist dust to prevent clogging.
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High-Temperature Media: For hot gas filtration; use insulated housing.
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HEPA Secondary Filter (H13/H14): For clean exhaust or recirculation, with ΔP monitoring.
5. Ducting & Hood Design – The 80% Efficiency Factor
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Proximity is key: Capture at the dust source with correct airflow direction.
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Smooth flow: Use long-radius elbows; replace tees with Y-branches.
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Consistent velocity: Avoid sudden reductions in diameter to prevent ΔP spikes.
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Testing & balancing: Install dampers and test ports for verification.
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Wear & condensation control: Use abrasion-resistant elbows and insulation where needed.
6. Explosion Protection & Safety
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Risk Assessment: Identify combustible dust, flammable vapors, or ignition sources.
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Mitigation Measures: Explosion venting, suppression, flame arrestors, grounding, and spark detection systems.
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Static Management: Conductive hoses/wheels, copper grounding wires, potential equalization.
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Safety Procedures: Lock-out/tag-out during maintenance and confined space checks.
Final design must comply with local explosion safety standards (ATEX/NFPA/OSHA as applicable).
7. Installation, Commissioning & Acceptance
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Pre-shipment: Verify specifications and functions.
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On-site testing:
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Airflow verification: Pitot tube or flow hood readings within tolerance.
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Pressure baseline: Record initial and steady ΔP ranges.
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Leak detection: Smoke or ultrasonic testing.
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Pulse and interlock check: Confirm cleaning cycles and delay sequences.
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HEPA integrity (if used): DOP/PAO test.
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Noise & exhaust: Measure dB levels and ensure rain/silencer setup.
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8. Maintenance & Digital Monitoring
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ΔP Trend Management: Establish baseline and alarm thresholds; rising ΔP = clogging, low ΔP = leakage.
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Energy Optimization: VFD-controlled airflow by ΔP feedback; reduce speed during off-hours.
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Smart Sensors: Monitor ΔP, current, airflow, temperature, humidity, VOCs, or dust concentration.
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Spare Parts: Keep 1–2 replacement sets of filters, solenoid diaphragms, gauges, and consumables.
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ESG Metrics: Track energy per kg of dust, water usage (wet systems), and downtime hours.
9. Frequently Asked Questions (FAQ)
Q1: What if airflow is insufficient?
Check duct blockage, damper position, and simultaneous-use ratio. Measure ΔP vs. flow curve; upgrade fan or add pre-separator if needed.
Q2: Why does pressure drop increase rapidly?
Likely sticky or oily dust; consider oil-repellent filters, pre-coating, stronger pulse cleaning, or dehumidification.
Q3: Do I need HEPA filters?
Yes—for fine dust or clean exhaust (H13/H14). Always install ΔP gauges before and after the HEPA.
Q4: Is explosion protection mandatory for combustible dust?
Conduct a risk assessment; typically recommend explosion venting + isolation + grounding.
Q5: How often should filters be replaced?
Use ΔP trend monitoring rather than fixed schedules—intervals vary by process.
Q6: How to reduce night-time noise?
Use low-noise blower models, silencers, acoustic enclosures, and vibration isolators; outdoor setup if needed.
Q7: How to estimate power consumption?
Power ∝ Airflow × Pressure. Reduce ΔP using optimized duct design, pre-separation, or VFD control.
Q8: Best practices for fine dust (<5 µm)?
PTFE/Nano membrane filters, uniform airflow distribution, HEPA secondary filtration, and condensation control.
10. Quick Purchase Checklist
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Target airflow (CMM) and pressure (Pa)
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Dust characteristics: particle size, stickiness, combustibility, moisture, temperature
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Site constraints: noise limit, space, indoor/outdoor, HEPA need
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Filter type: PTFE, nano membrane, anti-static, oil-resistant
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Cleaning system: pulse pressure, ΔP-triggered
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Safety features: venting, suppression, isolation valve, spark detection
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Testing: airflow, ΔP, leak, noise acceptance
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After-sales: spare parts, training, warranty terms
11. Case Example: Fine Powder Weighing Station (Graphite / Color Pigment / Flour)
Objective: Prevent dust escape and cross-contamination in weighing area.
Design Focus:
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Capture velocity 1–1.5 m/s at hood face.
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Use PTFE / anti-static nano membrane filter.
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Add inlet baffle and pre-separator for coarse dust reduction.
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Apply HEPA H13/H14 secondary filtration with ΔP monitoring.
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Implement explosion protection (venting, isolation, grounding) as per powder type.
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Ensure electrical circuits have potential equalization.
12. Common Mistakes to Avoid
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Judging by motor HP only, ignoring airflow and pressure.
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Neglecting pressure loss in the most critical branch.
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Poor hood design and incorrect airflow direction.
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Ignoring grounding or explosion isolation for combustible dust.
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No ΔP baseline or maintenance record.
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“It’s suctioning fine” — but no measured airflow, ΔP, or leak test.
13. Pricing & Total Cost of Ownership (TCO)
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CAPEX: Equipment, ductwork, installation, controls, explosion-proof accessories, HEPA, silencer.
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OPEX: Electricity (∝ airflow × pressure), filter replacement, maintenance, and downtime.
Cost Reduction Strategies:
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Optimize hood and duct design → lower ΔP.
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Add pre-separation → reduce filter load.
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Use VFD + closed-loop ΔP control → match demand dynamically.
14. Conclusion
There’s no “one-size-fits-all” dust collector.
Choose the right combination of source capture, airflow, static pressure, filter media, and safety design—and you’ll secure stable performance, energy efficiency, and regulatory compliance.
If you already have suction point lists or site sketches, organize your data and contact YUCHA’s engineers for an optimized solution and budget estimation.
Otherwise, our team can help you evaluate dust types and recommend the most effective industrial dust collection system tailored to your facility.