Top 5 Mistakes to Avoid with Dust Collection Filters

At FabCo Industrial Services, we’ve seen dust collection systems fail prematurely due to preventable mistakes. The good news is that with correct installation, good maintenance and cleaning practices, and proper understanding of capacity, your system can last a long time.

Here are the top five mistakes to avoid with your dust collection system. If you need immediate service, please contact us or call us at (800) 473-5251 here:

1. Improper Filter Installation and Sizing

One of the most critical mistakes is to perform an incorrect filter installation or use improperly sized filters.

Some facilities may attempt to save money by installing filters themselves or even use generic replacements that don’t match their system specifications.

Common filter installation errors:

Installing filters with incorrect orientation
Failing to properly seat filter cages
Using filters with wrong pleat spacing or media type
Inadequate sealing between filter and housing

Poor installation can lead to a bypass, where unfiltered air carrying dust particles escapes the system. This not only reduces collection efficiency but can cause premature wear on downstream equipment and create safety hazards.

FabCo’s solution: When you call us, we can discuss proper filter sizing based on your specific airflow requirements, dust characteristics, and operating conditions. We provide professional installation services that guarantee proper sealing and optimal performance from day one.

2. Not Understanding Temperature Limitations

Incorrect temperature in your dust collection system is a leading cause of premature filter failure.

Some operators may push their systems beyond recommended temperature limits, especially during peak production periods or when processing heated materials.

Temperature-related failures occur when:

Operating temperatures exceed filter media specifications
Sudden temperature spikes damage filter fibers
Inadequate cooling allows hot particles to reach filters
Steam or moisture creates temperature fluctuations

Excessive heat can cause filter media to shrink, melt, or become brittle, leading to tears and system failure. High temperatures also accelerate chemical degradation of filter materials.

FabCo’s solution: Our technicians can help you select temperature-resistant filter media appropriate for your application and recommend proper cooling systems. Our monitoring solutions can alert you to dangerous temperature conditions before damage occurs.

3. Chemical Exposure and Compatibility Issues

Chemical compatibility is often overlooked when selecting dust collection filters.

Many facilities assume all filters are created equal, but different industrial processes produce dust with varying chemical properties that can attack filter media. Chemical damage occurs from:

Acidic or alkaline dust particles
Solvent vapors in the airstream
Reactive chemicals that degrade filter fibers
Moisture combined with chemical contaminants

Chemical attack can cause rapid filter degradation, leading to holes, tears, and complete system failure. In severe cases, chemical reactions can create safety hazards or toxic byproducts.

FabCo’s solution: Our engineers analyze your specific dust characteristics and process conditions to recommend chemically compatible filter media. We offer specialized filters designed for challenging chemical environments, including PTFE membrane filters and chemically resistant synthetic materials.

4. Poor Maintenance and Cleaning Practices

Make sure to implement a routine maintenance and cleaning schedule for your dust collection system to avoid an expected failure.

Poor maintenance can lead to a number of issues, such as reduced airflow, increased energy consumption, and filter failure. Dirty filters also create back-pressure that can damage blowers and other system components. Common maintenance mistakes include:

Ignoring differential pressure readings
Failing to inspect filters regularly
Using incorrect cleaning procedures
Allowing dust buildup on clean-side components

FabCo’s solution: We provide comprehensive maintenance programs that include regular inspections, differential pressure monitoring, and scheduled filter replacements. Our predictive maintenance approach helps identify potential issues before they become costly failures.

5. Overloading the System Beyond Design Capacity

Some facilities may gradually increase production without considering the impact on their dust collection systems.

This leads to overloading, where the system handles more airflow or dust than originally designed for.

Overloading occurs through:

Increased production rates without system upgrades
Adding new dust-generating equipment
Processing different materials with higher dust loads
Inadequate system capacity from initial design

Overloaded systems experience reduced collection efficiency, increased filter wear, and higher operating costs. The entire system operates under stress, leading to premature failure of filters and equipment.

FabCo’s solution: We conduct thorough system assessments to determine if your current setup can handle increased demands. When upgrades are needed, we design solutions that accommodate growth while maintaining optimal performance.

Need Baghouse Troubleshooting Help? Contact FabCo Today!

Don’t let these common mistakes cost you thousands in downtime and premature filter replacement. FabCo Industrial Services offers comprehensive dust collection solutions, from initial system design to ongoing maintenance like HEC cleaning and filter replacement services. We provide baghouse filters, shaker filters, and pulse jet filters.

How We Can Help:

The FabCo team helps you:

Select the right filters for your specific application
Implement proper installation
Develop monthly, semi-annual, or annual maintenance programs
Increase capacity if needed
Baghouse valve rebuilds
Troubleshoot any current problems with your dust collection system

If you’re ready to optimize your dust collection system, please contact FabCo Industrial Services today for a service! Our experienced technicians will assess your current system, identify potential issues, and recommend cost-effective solutions that maximize performance and reduce downtime.

Contact Us:

To get started with a baghouse cleaning, maintenance, or troubleshooting service, please contact our team at (800) 473-5251 or email us at sales@fabcoind.com.