Customer Profile
Our client faced significant challenges with their dust collection system, which had installed 720 filter bags measuring 4m in length, covering a filter surface of 1497 m².
Despite the 4m long bag filters, the filter collector was undersized, resulting in a high differential pressure of 28.9 mbar, which is significantly above the optimal range of 16-18 mbar. Additionally, the emission level exceeded 30 mg/m³.
To address this, a new dust collector was reconstructed using 576 pleated bags from Hengst Filtration, which significantly improved the system's efficiency.
Location: Slovenia
Dust type: Steel grinding dust
Key Results
96% decrease in emissions
31% increased filtration surface
2m shorter filter resulted in a larger Dropbox and less abrasion
Lower pressure drop
High emissions and short filter lifetime
Before switching to pleated bags from Hengst Filtration, the client relied on traditional filter bags, which had a service life of only three months due to abrasion.
The first installation of Hengst pleated bags marked a significant improvement, delivering three years of continuous operation without any unscheduled maintenance. Emission levels were reduced by 96%, and the high differential pressure dropped from 28.9 mbar to a stable range of 16–18 mbar.
Impressed by the long service life and consistent performance, the client returned to Hengst Filtration with a new order. The next scheduled changeout will again utilize our pleated filter technology, reaffirming the efficiency, durability, and reliability of our filtration solutions.
Challenges
- High emission levels
- Poor filter bag quality, causing rapid deterioration and a shorter lifetime (3 months)
- High differential pressure
- High energy consumption
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: 576 pleated bags
Filter media: Spunbond polyester with ePTFE membrane
Filter media area: 3,4m²
Significantly lower emissions, lower pressure drop, and better filter cleanability
The filtration system was upgraded with 576 Top Loader pleated bags, equipped with 3,4m² spun-bond pleated polyester media. This upgrade provided 3 years of uninterrupted operation without any unscheduled maintenance.
General System Information
| Parameter | Data |
| Air flow in unit | 55.000 m³/h |
| Dust Type | Steel grinding dust |
| Collector running hours | 7600 hours/year |
Technical Data
| Before | After | |
| Filter model | Conventional filter bag | Top Loader CPB pleated bag |
| Filter media | Polyester needlefelt | Spun bond polyester with ePTFE treatment |
| Length [mm] | 4020 | 2070 |
| Number of filter bags / cartridges | 720 | 576 |
| Filration surface in each filter bag / cartridge [m²] | 2,08 | 3,40 |
| Filtration surface in entire system [m²] | 1497 | 1958 |
| Emission mg/Nm³ | > 30 | 1 |
| Pressure drop mbar | 28,9 | 16-18 |
From High Emissions to High Efficiency
By adopting Hengst Air Filtration's pleated bags, the company not only enhances its compliance with environmental standards but also realizes cost savings and improves the longevity and efficiency of its filtration systems.
96% emission reduction
Emissions have been reduced to 1 mg/m³, from the previous levels of above 30 mg/m³.
Reduced DeltaP
The high differential pressure was normalized from 28.9 mbar to the ideal range of 16-18 mbar.
Advanced Manufacturing Technology
- Surface Area Increase: Upgrading to pleated bag filters has resulted in a 30% increase in the filter surface area.
- Material Upgrade: Pleated bags with Spunbond polyester and ePTFE membranes offer superior filtration performance, lower pressure drop, enhanced cleaning efficiency, and greater durability compared to traditional polyester needlefelt filter bags. These advantages translate into cost savings, reduced downtime, and improved overall system efficiency.
- Weltech Technology: The use of ultrasonic welded bands ensures a perfect fit and equal pleat distance, enhancing the overall performance and durability of the filters.
Get in touch
Contact our team for any questions and support regarding Filter Cartridges, Pleated Bags & Flat Cells
sales.nakskov[at]hengst.com