5 Reasons Why Industrial Bag Filters Are Essential for Manufacturing Plants

Bag filters come in many different styles. They can be made of woven mono- and multi-filament fabrics, needle felts, or melt-blown nonwovens. Felted filter fabric uses randomly positioned fibers in a scrim-like structure to trap particulates and other contaminants. Pulse jet baghouse systems use bursts of air to dislodge these contaminants and send them to a collection hopper below.

Reduce Dust and Particles

When dust and other debris build up inside a plant, industrial bag filters VA effectively reduce contamination. They improve product quality, minimize process downtime caused by clogs or pressure drops, and protect workers from airborne pollutants. Industrial filter bags are available in various materials to suit different applications and temperatures. Woven mono- and multi-filament fabrics, needlefelts, and melt-blown nonwovens are typically used in filter bags. A PTFE membrane coating on some filters provides added resistance to chemical and high-temperature environments. It also allows for a more porous filter surface to improve dust cake release and filtration efficiency. The result is lower pressure drops, higher air-to-cloth ratios, and improved collection efficiency.

Reduce Emissions

Bag filters are a vital component for controlling particulate emissions in industrial units. They are used in many industries, including power plants, steel mills, cement kilns, nonferrous metal smelters, pharmaceutical factories, food and beverage manufacturers, and chemical industries. Emissions are closely regulated in these plants, and failure to comply could result in fines, loss of production, or even plant shutdown. Using baghouse filters helps reduce particulate emissions and improves air quality inside the plant while meeting local and national emission standards. The most common bag filter type is a shaker, reverse air, or pulse jet bag filter. All three types provide excellent operating efficiencies. However, the pulse jet bag filter performs better because it is less prone to leaks than the other two.

Increase Product Quality

With a focus on food safety, many plants rely on industrial bag filters to ensure high-quality product production. This is especially true for companies processing foods that are known allergens or other potential contaminants. Operating continuously and without requiring shutdown for filter maintenance is crucial for these plants. Pulse-jet cleaning uses air to momentarily interrupt the collection process to clean the bags, allowing the compartment to stay online. In the metallurgical industry, smelling nonferrous metals takes a lot of energy. This creates significant particulate emissions that environmental agencies regulate. Filter systems that help maintain compliance with these regulations will save fuel and money.

Reduce Maintenance Costs

The plant needed a reliable and efficient way to keep its production running without the interruptions caused by filter changes. Filter change-outs cost the customer thousands of dollars per hour in lost production. Liquids must be filtered in chemical processing plants to ensure product quality and protect equipment. Industrial bag filters are an essential tool in ensuring this quality and efficiency.

Unlike electrostatic precipitators, which require the entire dust collection system to be shut down during cleaning cycles, pulse jet bag filters continuously clean the bags with a blast of air that momentarily interrupts the dirty gas stream. This keeps the compartments online, filtering, and prevents expensive and labor-intensive shutdowns during cleaning. By using pleated bags that offer longer lifespans and lower stabilized pressure drops, the customer could decrease the frequency of bag change-outs from every 10 to every 60 minutes — significantly reducing maintenance costs.

Reduce Waste

Waste is anything that doesn’t add value for customers and costs the company money. This may include unneeded production, excessive inventory, inefficient processing, etc. Identifying waste is an essential first step to eliminating it. For example, bag filters help non-ferrous metal smelters control their particulate emissions. This helps them meet regional EPA requirements and maintain a clean environment. Otherwise, they could face expensive fines and regulatory scrutiny. Another way to reduce waste is by ensuring all waste is disposed of according to appropriate health protocols. This includes any solvents used in the manufacturing process. These can be reduced by using more innovative systems, limiting use, and treating effluents to remove as many harmful substances as possible before disposal. Lastly, efficient inventory management can help reduce waste by controlling how many raw materials are purchased.