Efficient operation of a dust collector is only possible with regular maintenance. Three major factors must be considered together - filter life, energy consumption and system downtime. It is easy to explain why it is a myth and a false misconception that it is always more cost-effective to replace individual filters.
The work of the dust collector is based on an exact calculation of the air-media ratio (AMR) - that is, the ideal ratio of filtered air volume and available filtration area. The measure of all things is the size of the particles to be filtered. As a rule of thumb, the smaller the particles, the lower the filtration rate.
Of course, the dust collector should always perform its task with consistent quality and provide a constant volume of air - regardless of whether the filters have just been replaced and are new, or whether they are already loaded with dust. For this purpose, the air flow is controlled accordingly with an air flow regulator, because the fuller the filters become, the higher the resistance becomes and possibly leads to a higher pressure loss in the system. If, on the other hand, a clean filter were to draw in too much air without regulation, it is possible, especially with very small particles, for these to penetrate deep into the outer fibers of the filter and become trapped there. This phenomenon of so-called deep loading of the filter is irreversible, and inevitably leads to a shortened service life of the filter, the resistance increases more rapidly, and the filter must be replaced again.
If only one filter or only a part of the filters is replaced now, the resistance is not the same across all filters. The new filters then receive a significantly higher airflow until the resistance in all filters is the same again. As mentioned earlier, the higher airflow usually causes a greater depth loading and thus an extremely shortened life. Also, the collector runs at a higher pressure drop.
All this leads to a shortened lifetime of all filters in the system, more compressed air consumption and thus higher energy costs. And of course, frequent individual filter changes also lead to more downtime for the system in addition.
In the long run, it is more expensive not to always change all filters for possible short-term cost reasons. If a system shows a high delta-p value, all filter cartridges should be replaced completely. The thought "My system has 24 cartridges. I don't have that much money now. I will change 5 cartridges, then my delta-p will come down a bit" is completely wrong. After all, the delta-p value is measured as an average in the entire system and the air flow is aligned to it. With differently loaded filters, the air flow is no longer suitable for any of the filters, the system no longer works as efficiently as it could, the delta-p value is reached again more quickly and the system stops more often.
Complete filter replacement for dust collectors is easy on the budget and reduces downtime and energy consumption.