Pleated Baghouse Filters: A Smarter, More Cost-Effective Solution!

Traditional Filters vs. Pleated Filters

fiberglass baghouse filter

Made from a variety of materials, filter bags can be used in high temp, high dust loading, abrasive, corrosive and high humidity applications

Traditional baghouse filter bags have been the standard in dust collector for nearly 100 years and they continue to be the most common type of filter used across nearly all industries and applications. Their wide use, and simple construction means they present the lowest cost per filter option.

However, when the time for your next filter replacement comes, are traditional baghouse filters always the most cost effective option when all cost factors are considered? In many applications this is not the case. One choice that should be given more consideration is to replace your existing traditional filter bags and cages with pleated filters.

This article will examine exactly what are pleated baghouse filters and what are their advantages over traditional bags and cages. 

What are Pleated Baghouse Filters

pleated filter design

Pleated filter elements have many folds of the fabric that provide a greater surface area of filter cloth in a shorter length, allowing for improved air-to-cloth ratios in the same space

As one of the latest technologies in industrial dust collection, pleated filters improve on the design of traditional bags by packing more filter fabric into a smaller space. 

 

 

 

 

 

 

 

 

Additionally, the shorter overall filter length also creates additional space underneath the bottom of the filters, keeping the filters above the dirty inlet gas stream.

traditional filter bags versus pleated filters

Shorter filter length reduces abrasion problems caused by incoming dust particles striking the filters and further slows the incoming air, which improves filter dust cake release when the filters are pulsed

Another advantage over traditional filters is that they do not require separate cages, as the bag and cage are combined into a one-piece construction. This means no more separate cage purchases and easier storage of filters. Due to these reasons, they  are more efficient at removing particulate than traditional bags and last longer, sometimes up to 2 times as long. Pleated filters are designed to operate with today’s high demand production demands and can replace existing bags and cages in most standard pulse jet baghouses without any modifications required. 

Why use Pleated Filters Over Traditional Bags and Cages

pleated filter graphic

As noted, there are compelling operational and performance benefits to switch from traditional filters to pleated filter elements. But there are also significant financial advantages. The use of pleated filters in today’s high production demands can reduce costs by up to 60%. How is this the case? Let’s examine some of the benefits of switching to pleated filters. 

 

  • — Reduction in Total Number of Filters:

    The total number of filters required is reduced due to the overall filter cloth area being increased when using pleated filters. Less filters are required for the same filtering efficiency. 

 

  • Pleated-Filters-Install-Step-1

    Installation can take 50% less time than it takes to replace traditional filters

    — Easier Installation:

    The reduction in the number of filters being installed results in faster changeouts, less downtime and lower installation costs. Also the one-piece unitary design means there is no cumbersome operation to remove and reinstall the cage and bag together, therefore installation can take 50% less time than it takes to replace traditional filters. 

 

  • — Reduction in Compressed Air:

    With less physical filters and an improved filter area, pleated filters load dust better and are easier to clean. This leads to a significant reduction in the use of compressed air during the cleaning cycle.

 

  • — Increased Lifespan:

    Shorter length of filters and a reduction in cleaning, results in pleated filters experiencing less wear and tear during operation. This means pleated elements commonly last from 25 to 75% longer than filter bags. Sometimes as much as 2 to 3 times longer. Longer lifespan means replacing filters less often.

 

  • — Improved Operation and Greater Capacity Through Increased Filter Area:

    Pleated Filter elements can dramatically improve operation costs by increasing capacity, by decreasing emissions, reducing electricity usage. Pleated elements can effectively increase the amount of filter media inside a collector by as much as 700%.

bag filter square feet area versus pleated filter square feet area

With the greater amount of filter media, operators can either:

  1. Keep the airflow the same and thus increase the air-to-cloth ratio for improved performance and filter life
  2. Increase airflow to have a greater baghouse capacity of a baghouse, possibly allowing for the combination of several dust collection systems into one larger unit and in turn reducing operation costs. 

Conclusion - Pleated Filters Provide Significant Advantages In The Right Application

what is cheaper: a filter bag or a pleated filter?

Traditional filters usually mean lowest cost per filter, but with pleated elements the overall short term and long term cost of replacing and maintaining your baghouse can be dramatically reduced

There are many advantages to switching from traditional to pleated filters.

In certain cases however, switching to pleated filters will not be a viable option. For example, pleated filters are not advisable for high temperatures or  when the airstream contains highly corrosive gases. Higher temp versions do exist, but they have significantly higher costs per filter and may only be viable in applications where improving dust collector performance will provide significant financial upside and with few to no other options available to do so.   

In summary, from cost savings to improved efficiency and longer lifespan, pleated filters can be a game-changer for your dust collection system.

To find out more information on the pleated filters and to discuss the option of converting  your baghouse to pleated filters, please contact us at Baghouse.com

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