Dust collection systems rarely fail overnight. More often, they underperform quietly—until buildup, plugging, excessive wear, or safety risks force a costly shutdown. In most cases, the root cause isn’t the quality of the equipment; it’s the design assumptions that went unchallenged at the start.
Use this checklist to identify the five common design-stage decisions that quietly undermine long-term performance.
Many systems rely on generalized "rules of thumb" for air velocity. This is a gamble. Velocity must be precisely tuned to the material's particle size, shape, moisture content, and bulk density. (Note: Minimum Transport Velocity (MTV) varies by material density. Light fibrous materials (lint) may require only 2,500 fpm, while heavy industrial dusts often require 3,500–4,500 fpm. Always calculate based on your specific material.)
It’s a common misconception that oversized ducting provides a "safety margin." In reality, it does the opposite.
System resistance (Static Pressure) is often entered as a fixed value during design and never revisited. However, filter aging, media selection, and cleaning cycles mean your pressure requirements are constantly shifting.
Systems with numerous slide gates often rely on manual balancing after installation. While gates are necessary, they shouldn't be a crutch for poor design.
A fan that technically "hits the CFM" can still be the wrong tool for the job.
When a system fails, the "fingerprints" are almost always visible in the original design documents. Good systems don’t rely on hope; they rely on verified fundamentals.