Switch to Pleated Filters for Substantial Savings
Author: Lisa Frank
An increasing number of industries are switching from standard bags and cages to more advanced dust collection technology available today: pleated filters. Their bags contain more folds of fabric in a smaller area than the traditional bags and cages. Because pleated elements combine the bag and cage into one piece, separate cages are no longer necessary. This enhanced construction offers substantial savings on operation and maintenance. How so?
Six Advantages of Pleated Filters
Increased Cloth Area. The primary benefit of pleated elements is that they maximize usable fabric. On average, a pleated filter measures half the average length of a standard bag and cage and yet provides two to three times more the cloth area!
Improved Baghouse Operation. Since pleated elements can effectively double (or more) the capacity of a baghouse, multiple dust collection systems can thus be combined into one unit. Production can increase without the blockages or expense that comes with a new baghouse. Pleated filters typically produce healthier emissions than standard dust collector bags. This helps with the everchanging regulations set out by the federal and state environmental departments.
Easier to Clean. More filter area allows pleated elements to load dust better, which translates into fewer cleaning cycles and the ability to use cheaper compressed air. Converting to pleated filters often reduces compressed air usage by up to 50%!
Highly Efficient. Fewer cleaning cycles also lessens wear and tear. As a result, pleated filters typically last up to 75% longer than bags! Not only are these long-lasting filters replaced less often, they are also more efficient. One pleated filter can perform the same amount of work as two bags!
Less Costly to Install. Removing and replacing bag and cage assembly is complicated, cumbersome, and time-consuming. The manpower, labor hours, and system downtime needed to change dust collector bag filters is a large expense for most facilities. In contrast, it takes about half as much time to change a one-piece pleated element than a traditional filter bag. The ease of installation minimizes the effect on production and maintenance.
- Reduced Abrasion and Grain Loading. The bottoms of bag filters can get worn down by incoming air that is laden with abrasive compounds such as sand, metal dust, silica, asphalt, and cement. But since pleated filters are shorter than bags, they rest above the high-speed abrasive air. The enlarged chamber below the pleated filter prevents larger particles from even contacting the filter (aka lower grain loading), thus extending the life of the filter.
As long as exposure to high temperatures and corrosive gases is minimal and velocities are kept under certain thresholds, pleated filter elements can supply your plant with drastic energy savings and meet a higher production demand. Case studies have shown that after switching to pleated filters, plants can expect to see returns on investment within as little as 3 to 6 months! As the cost of maintenance decreases and the life, performance, and capacity of the filters increases over time, these savings will continue to climb.
Contact AirMax today to learn more about how switching to pleated dust collector filters can benefit your plant or warehouse!