Dust Collection Retrofit – Food Processing Plant
The Challenge
A regional food processing plant was operating with an aging dust collection system that was no longer meeting performance or safety standards. The system served ingredient handling and packaging lines, collecting flour and powdered ingredient dust. Concerns included combustible dust hazards identified by an NFPA audit, poor dust capture leading to housekeeping issues and air quality complaints, aging ductwork with leaks and corrosion, and an undersized collector that couldn't handle current production volumes.
The plant had a narrow three-week shutdown window during the summer when production volumes were lowest. The new system needed to be fully operational before production ramped up for fall harvest.
Our Solution
Hudson Sheet Metal provided a complete design-build dust collection system replacement. We reviewed existing system performance issues and production requirements, then designed a new system with proper duct sizing, transport velocities, and combustible dust safeguards. We specified a larger, more efficient cartridge-style dust collector with explosion venting per NFPA requirements.
We fabricated 1,800 linear feet of new stainless steel ductwork in our shop, with prefabricated modular sections for faster field installation. All ductwork was designed for smooth interior surfaces to minimize dust accumulation. Crews mobilized on day one of the shutdown window, removed old ductwork and collector, and installed the new system over 14 days. The system was tested and balanced, achieving design airflows at all capture points.
Results
The new dust collection system was commissioned and fully operational on schedule, allowing the plant to restart production as planned. On-time startup with zero delay, improved performance achieving design airflows and eliminating dust accumulation issues, full safety compliance meeting NFPA combustible dust standards and resolving insurance concerns, and proper clean-outs and inspection access for ongoing maintainability.
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