How Frequently Do I Need to Clean My Electrostatic Filters?

One of the most common questions we hear is:

“How often do electrostatic filters need to be cleaned?”

The honest answer is—it depends. But let us explain.

Every manufacturing facility is different, and several factors affect how quickly electrostatic collection cells and ionizers become dirty. Two facilities running the same equipment may require completely different cleaning schedules depending on their operating conditions.

What Affects Cleaning Frequency?

Several factors determine how often your electrostatic air cleaner should be serviced.

Hours of Operation

The longer your air cleaner operates each day, the faster contaminants accumulate on the collection cells and ionizers.

A system operating 24 hours a day will require more frequent cleaning than one operating only a single shift.

Pollutant Load

Pollutant load refers to the concentration of contaminants entering the air cleaner.

Heavier smoke or mist loads will cause the filters to become dirty much faster than lighter applications. 

    Processes that  create heavier loads are:

• Hard materials
• Heavy cuts
• Hot coolants
• High speeds
• High Pressure coolants
• Suction point is too close to the cutting head.

Type of Pollutant

Different contaminants affect electrostatic filters differently.

Common contaminants  ranked worst to easiest regarding filter life

• Sticky plastic or rubber smoke

• Welding fume
• Oil smoke
• Water-soluble coolant mist with smoke
•  Oil mist
• Water Coolant no smoke
• Ambient contaminants 

Each contaminant loads the collection cells differently and may require a different cleaning schedule.

Air Cleaner Design

Not all electrostatic air cleaners are designed the same.

Brands such as SmogHog®, MistBuster®, Tri-Mist®, Trion®, and Aerocology® have different collection cell designs, airflow patterns, and filtration capacities. As a result, cleaning intervals can vary from one manufacturer and model to another. In general though there are two main differences, one depth of collection cell and number of filter passes.  A deeper collector lasts longer and more filter passes lasts longer and allows for removal of a denser cloud of smoke.

Airflow Speed

Air velocity through the air cleaner also affects service intervals.

Higher airflow can move more contaminants through the unit, causing the collection cells to load more quickly. Each manufacturer may have different recommenations typically 450 Feet per minute accross the filter is perfect.  Too fast and the particles may not move over to the collection plate fast enough to stick to it before exiting the filter.

How Do You Determine the Correct Cleaning Schedule?

Since every application is different, the best cleaning schedule is determined by monitoring the performance of the air cleaner.

Here are three simple ways to determine when your filters need service.

Post filter, usually an aluminum mesh filter following the collection cell.

One of the easiest indicators is this filter.

If the last filter is becoming dirty, it means contaminants are passing through the collection cells instead of being captured.

When this happens, it was  time to clean the collection cells and ionizers a bit before this check. If its still clean then a longer frequency is possible.

Examine the Collection Cells

Inspect the collection cells during routine maintenance.

Normally, contaminants collect near the front of the plates first. As the front of the collection cell becomes loaded, particles begin collecting farther back through the cell.

If contamination extends deep into the collection cell, cleaning should be scheduled soon. Note always look from the top down and every other plate should be clean as they push the contaminant to the collection plate.

Use Trial and Error

For new installations, the best approach is often to begin with a short estimated cleaning interval and adjust based on actual operating conditions.

Most facilities require cleaning somewhere between one and six months, depending on the application.

If you notice:

• Smoke blowing through the air cleaner
• Dirty post filters
• Flashing indicator lights
• Reduced filtration performance

The cleaning interval should be shortened or filter capacity increased.

If the collection cells remain relatively clean and performance is still excellent, you are able to extend the cleaning interval.

Preventative Maintenance Saves Money

Cleaning electrostatic filters on the proper schedule helps:

• Maintain filtration efficiency.
• Extend the life of collection cells and ionizers.
• Reduce electrical problems.
• Prevent unnecessary downtime.
• Improve workplace air quality.

Waiting too long between cleanings can reduce collection efficiency and increase the likelihood of damaged cells, electrical arcing, and costly repairs.

Filtration Systems of Troy, Michigan and Bee Clean Specialties have both serviced SmogHog® and MistBuster® electrostatic air cleaners throughout Michigan for many years. Today, Bee Clean Specialties continues providing preventative maintenance, filter exchange programs, troubleshooting, and onsite service for electrostatic air cleaners throughout Michigan, Illinois, Indiana, Ohio, Wisconsin, Minnesota, and the surrounding Midwest.

If you have questions about how often your electrostatic filters should be cleaned, Bee Clean Specialties is always happy to help. Call us at 847-451-0844 to discuss the best maintenance schedule for your facility.