Here's how to avoid the most common mistakes in designing a dust extraction system

In industrial dust collection systems, the quality of the equipment itself is only half the story. One of the most common causes of poor suction power or clogged systems is improperly designed and installed dust collection piping and equipment. Experts at Suomen Imurikeskus Oy repeatedly encounter sites where dust extraction systems have been built using standard HVAC components and ventilation fans that are too small. This results in extra costs and significant losses in performance.

Common Mistake: Designing Dust Removal Systems According to HVAC Ventilation Regulations

Often, the design of ductwork for chip and dust removal ends up being handled by designers who specialize in a building’s general ventilation system. Although there is plenty of HVAC expertise available, the principles of ventilation and dust removal differ radically. Whereas in general ventilation, clean air flows through the duct at a speed of, say, about 2 meters per second, in dust extraction the velocity is often more than ten times higher (e.g., 20–25 m/s), and the air carries physical, sometimes even heavy, material.

If the system is installed using a thinner-than-usual spiral-seam duct with standard corner pieces, several problems will arise right from the start:

1. Suction power is lost along the way: Incorrect connections, overly sharp bends (e.g., straight 90-degree T-joints), and corrugated pipe bends cause severe turbulence and disrupt the flow. Suction power is already lost before it reaches the actual dust extraction point.
2. Blockages: When chips, sawdust, or heavy dust pass through the pipe, power losses caused by faulty components cause the material to accumulate in the bends and branches of the piping, eventually leading to a blockage of the entire system.
3. Pipe Wear: Heavy materials moving at high speeds quickly wear through inexpensive plumbing pipes.

How is a power loss identified and corrected?

If you find that cleaning is taking too long or that your production environment isn’t staying clean despite your equipment, Suomen Imurikeskus Oy’s technical expertise is at your disposal.

We measure the system’s specified capacity and compare it to the actual airflow at the end of the ductwork. This allows us to calculate the actual airflow and, by examining the sizes and components of the ductwork, identify the problem areas where capacity loss occurs. Often, experience alone is enough to spot the problem at a glance: piping made of the wrong materials or with excessively sharp bends is an obvious risk factor.

An important piece of expert advice is this: it isn’t always necessary to replace the entire system. Sometimes it’s enough to remove the inefficient HVAC piping and install in its place a properly calculated, specialized piping system designed for dust removal, complete with the correct Y-branches and more robust components. At best, this optimization can save you from unnecessarily replacing a system that is still fully functional.

Are power losses a problem in your production facilities?

Equipment suppliers and designers are responsible for taking into account the system’s life cycle and overall performance. Here at Suomen Imurikeskus Oy, we have decades of experience in sizing effective dust extraction systems. We collaborate with building contractors and HVAC designers, among others, to provide the correct calculation and sizing principles for dust and chip extraction. Our goal is always to ensure that the installed solution maintains its suction power from the equipment all the way to the discharge point.

Contact the experts at Suomen Imurikeskus Oy, and we'll make sure your ductwork and vacuum system are properly sized!

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