Customer Profile
Our client, a UK-based metal processing facility, experienced persistent issues with their welding and arc air cutting dust collection system.
The system used 408 conventional filter bags, each 3000 mm in length, with needle felt media and ePTFE membranes. These bags frequently failed due to abrasion from internal metal supports, leaks from stitch holes, and poor seals caused by metal burrs on the cell plate.
As a result, emissions reached the second filtration stage of the HEPA filters, leading to high maintenance demands and reduced operational efficiency.
Location: UK
Dust type: Manganese Dust
Key Results
Decrease in emissions
Less abrasion and longer lifetime
Interim maintenance checks eliminated
Enhanced the system's reliability and performance
High emissions and short filter lifetime
The system was retrofitted with 408 pleated filter bags made with spunbond polyester with ePTFE membrane, reducing bag length to 1355 mm and increasing filter surface area by 42% (from 465 m² to 800 m²).
This upgrade not only removed the filter media from the abrasion zone but also eliminated leakage paths and improved seal integrity.
Challenges
- High emission levels
- Poor filter quality, causing clogging of the second level of filtration
- Holes in the filter bags due to abrasion and the support cages
- Often unscheduled maintenance sessions
Replacement of filters with high performance pleated bags
The filtration system was upgraded with:
Type of Product: CPB - Top Loader Pleated Bag
Number of filters: 408 pleated bags
Filter media: Spunbond polyester with ePTFE membrane
Filter media area: 1,96m²
Significantly lower emissions, lower pressure drop, and better filter cleanability
The filtration system was upgraded with 408 pleated filter bags, equipped with 1.96 m² Spunbond polyester media with ePTFE membrane. This retrofit reduced the filter bag length from 3000mm to 1355mm and increased the total filter area from 465m² to 800m².
General System Information
| Parameter | Data |
| Air flow in unit | 25.000 m³/h |
| Dust Type | Manganese dust and fumes |
| Collector running hours | 1680 hours/year |
Technical Data
| Before | After | |
| Filter model | Snapband filter bag with bumper cuff | Top Loader CPB pleated bag |
| Filter media | Polyester needlefelt with ePTFE membrane | Spun bond polyester with ePTFE treatment |
| Length [mm] | 3000 | 1355 |
| Number of filter bags / cartridges | 408 | 408 |
| Filration surface in each filter bag / cartridge [m²] | 1,14 | 1,96 |
| Filtration surface in entire system [m²] | 465 | 800 |
Outstanding results followed shortly after implementation
Emissions significantly reduced
The new pleated bag filters significantly reduced emissions at the second stage of filtration (the HEPA filters) and in the working environment by eliminating leakage from stitch holes and ensuring a proper seal, thanks to the polyurethane top caps.
Pressure drop and maintenance demands reduced
Thanks to the 42% increase in filter media surface area, the air-to-cloth (ATC) ratio decreased, reducing the load on the system. No in-between inspections or maintenance were necessary after the upgrade.
Filter lifetime improved
By shortening the pleated bag length, the filter media was removed from the areas of abrasion.
Additionally, the larger dropout box allowed more coarse dust to settle before reaching the media, reducing wear and extending filter life.
Get in touch
Contact our team for any questions and support regarding Filter Cartridges, Pleated Bags & Flat Cells
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