Dust particles can severely affect the performance and output of any facility, be it from cross-contamination in food processing plants to causing health problems to workers. As such, properly managing the dust-filled air with dust collection systems is crucial in any industry.
But with the option of going with either a bag filter or a cartridge filter, which one should a business procure? Let’s uncover how these two filter types function, how they differ from each other, and how to choose the right one for the job.
Breaking Down Bag Filter Vs Cartridge Filter
To start the discussion, let’s answer the biggest question: what sets a bag filter apart from a cartridge filter? Here’s a quick breakdown of the key differences between bag filters and cartridge filters.
| Bag Filter | Cartridge Filter | |
| Simple Working Principle in the Dust Collection System | Trap particles on the filter media’s outer layer | Draws dust-filled air into the cylindrical filters |
| Design | Long, vertical bags | Compact and cylindrical |
| Efficiency | Handle larger particles and high volumes, but may have higher pressure drop with finer micron ratings. | Pleated designs offer lower pressure drops and higher flow rates for equivalent micron ratings due to increased surface area. |
| Filtering Surface | Small surface area, from 0.8 to 1.2 sq. m. | Larger surface area, covering 1.5 to 25 sq. m. |
| Material | Woven or felted fabrics treated to enhance filtration performance | Pleated paper or cellulose, spunbond polyester, nanofiber, PTFE-coated media |
| Applications | Woodworking, cement production, power plants, steel mills | Metalworking, welding, pharmaceutical, and food processing |
| Environmental Impact | Generate more waste if single-use. Some reusable options are available. | Cleanable versions are environmentally friendly; disposable versions contribute to landfills but may have recycling options. |
For a more detailed description of these differences, we’ve prepared some explanations for each point.
Working Principle
Baghouse Dust Collector
Baghouse dust collectors work on the principle of trapping the dust particles on the filter bag’s surface. Dust-filled air is directed through the filtration system, where the bags hold the dust particles while letting the clean air proceed.
Once the filter media gathers a suitable amount of dust particles, the bag filter is cleaned by either mechanical shaking or reverse airflow. The dust then falls into a collection system installed within the collector for disposal or recycling.
Cartridge Dust Collector
For cartridge dust collectors, the working principle is simple: capturing as many dust particles as possible on the cartridge. As dust-filled air passes through the cartridge, it filters the air by trapping the particles on its exterior. It then lets the cleaned air go through and eventually return to the facility.
When the dust cartridge reaches its limit, the accumulated dust is released from the filter using a pulse-jet cleaning mechanism. This pushes the dust out of the cartridge and into the built-in collection system, where it is retained until disposal.
Design
Bag Filter
A typical baghouse dust filter has three main components, namely the bag housings, filter bags, and the cleaning mechanisms. Bag housings hold the bags in place, while the cleaning mechanisms help remove the collected dust particles to allow continuous air filtration.
As for the filters themselves, these take the form of long sock-like bags made from woven or felted fabric material. The bag’s length, shape, and width depend on the setup requirements, making them highly versatile and flexible for any task.
Typically, bag filters are placed vertically on the filtration system to efficiently capture the particles as the air passes along the bags. However, a certain type called envelope filters is installed horizontally on the system. Additionally, other bag filters may also require baghouse filter cages to provide additional support for better dust filtration.
Cartridge Filter
Compared to the flexible, cloth structure of bag filters, cartridge filters are solid, cylindrical pieces with rigid pleats. The cartridge has three main parts: the filter cartridge, the housing, and the filter media. The housing usually provides the filter with a durable base, with the filter and filter media facilitating the separation of dust particles from the air.
Moreover, the cartridge features a hollow center that offers a couple of advantages:
First, it lets the air pass freely through the cartridge, thus allowing faster and more efficient filtration.
Second, it makes dust removal from the cartridge faster, as strong jets of air pulse within the hollow area and push the dust away.
Cartridge filter design is also taking innovative steps, like replacing the cartridge’s end cap with an internal cone. This increases the cartridge’s filtration area and makes cleaning the cartridge better.
Efficiency
Bag Filter
Bag filters excel in high-volume, low-pressure applications where capturing larger particles (5-200+ microns) is a priority. Their depth filtration mechanism allows particles to be trapped throughout the thick, porous fabric matrix, rather than just on the surface. This design enables the bags to handle significant contaminant loads without rapid clogging, making them ideal for industries such as mining, wastewater treatment, or food processing, where large volumes of liquid or air containing coarse particles must be handled continuously.
However, their efficiency decreases when targeting finer particles. At micron ratings below 10, the dense fabric structure creates a higher pressure drop as flow resistance increases, forcing pumps or fans to work harder to maintain throughput. This trade-off limits their suitability for precision filtration, although their high dirt-holding capacity ensures longer service intervals in moderate particle applications.
Cartridge Filter
Cartridge filters, especially pleated designs, prioritize precision and flow efficiency. The pleated media dramatically increases the effective surface area (up to 5x more than flat media), enabling higher flow rates at lower pressure drops, even at fine micron ratings (0.5-100 microns). This makes them ideal for applications requiring sub-micron filtration, such as pharmaceutical sterilization, semiconductor manufacturing, or drinking water purification.
Surface filtration cartridges (such as membrane filters) trap particles on the outside of the media, preventing clogging of the inner layers and maintaining consistent flow. Deep-bed cartridges, often made of sintered polymers or fiberglass, combine particle retention within the media with moderate dirt-holding capacity. Cartridges also adapt better to variable flow conditions-pleats prevent media collapse under pressure, ensuring stable performance.
Material
Bag Filter
Materials used in creating bag filters mainly depend on two factors: the industry purpose and the type of dust particles it is intended to filter. Some of the more popular materials for bag filter media include:
- Polypropylene – a thicker material known for high abrasion resistance
- PTFE – its superior corrosion resistance makes it an ideal material for handling gaseous contaminants
- Polyester – a material that offers adequate durability at a manageable cost, a perfect balance between the two.
Cartridge Filter
The two main materials popular with manufacturing cartridge filters are:
- Cellulose blends – a combination of cellulose and polyester, this material is preferred for its simple and inexpensive nature.
- Spunbond polyester – while it has better filtration capabilities and less pressure drop, this material can cost more.
To enhance the functionality of cartridge filters, a layer of special material can be added that prevents dust from penetrating the material. Some of these include:
- Nanofibers – a thin layer of nanofibers from <1 micron to <0.3 microns stops smaller particles from entering the cartridge.
- ePTFE – enhances filtration efficiency and reduces the risk of particles sticking to the cartridge. While it acts similarly to nanofibers, it lets the cartridge perform better at a higher material cost.
- Meltblown lamination – a layer of molten thermoplastic is blown on the cartridge, which improves filtration efficiency. However, particles may stick to the thermoplastic layer, which makes the cartridge harder to clean.
Filtering Surface
Baghouse Dust Collector
A bag filter’s filtering surface is based solely on the dimensions of the filter media. However, when partnered with an automatic cleaning system, it can handle high quantities of dust efficiently.
Cartridge Dust Collector
While cartridges have a larger filtering surface and are less bulky than bag filters, their pleated design can influence their filtration capacity. Compressed folds can reduce the filtration surface, while large volumes of dust stuck between the pleats can clog the cartridge.
Applications
Baghouse Dust Collector
Baghouse dust collectors can work in various industries, though they excel more in facilities with abrasive or grainy dust particles. If the workshop has high air volumes, heavy dust loads, and is a high-temperature location, bag filters will best suit in maintaining the constant flow of clean, dust-free air.
Key industries that benefit best with baghouse dust collectors are:
- Woodworking,
- Cement production,
- Power plants, and
- Steel mills
Cartridge Dust Collector
On the other hand, cartridge dust collectors shine in industries where the air is filled with fine dust particles. Where the utmost cleanliness is vital to the success and continuance of the operation, cartridge filters are there to get the job done.
Industries where cartridge filters work ideally on these industries:
- Metalworking,
- Welding,
- Pharmaceutical, and
- Food processing, among others
Environmental Impact
Baghouse Dust Collector
Bag filters, typically made from synthetic fabrics such as polyester or polypropylene, generate significant waste when used in disposable applications due to the need for frequent replacement in high-load environments.
However, advances in synthetic nonwovens (e.g., KLLC-820 and KLLC-860) have improved their dust holding capacity by 50-300%, reducing replacement frequency and waste generation. These depth filtration materials allow particles to penetrate the fabric matrix, delaying surface clogging and extending service life, reducing landfill contributions compared to traditional cellulose filters.
In addition, baghouse filters are critical in industrial air pollution control applications, such as calcium-based semi-dry flue gas desulfurization, where they trap sulfur dioxide and particulate matter, preventing harmful emissions. Their role in reducing airborne pollutants such as PM2.5, which is linked to shortened human life expectancy, underscores their indirect environmental benefits.
Cartridge Dust Collector
Cartridge filters, especially pleated types, often use materials such as cellulose, polypropylene, or PTFE membranes. While their initial production may involve energy-intensive processes, their compact, high-efficiency design reduces space requirements and reduces resource consumption during manufacturing and installation.
Reusable cartridges, such as Arkal’s self-cleaning systems, minimize waste by allowing repeated use with minimal water (0.5-1% of total flow) for cleaning. However, disposable cartridges contribute to landfill waste if not recycled.
Cartridges excel in precision applications such as pharmaceutical or drinking water purification, preventing contaminants such as microplastics or pathogens from entering ecosystems. Their lower pressure drop compared to bags also reduces energy consumption in high-flow systems, improving operational sustainability.
Cartridge Filter Vs Bag Filter’s Advantages and Disadvantages
Now that we’ve discussed the main differences between cartridge filters and bag filters, it’s time to look at their strengths and opportunities. Here’s a brief overview according to several key factors:
| Bag Filter | Cartridge Filter | |
| Filtration Capability | Heavier dust loads | Higher filtration |
| Particles Captured | Captures larger particles | For finer particles |
| Flow Rate | Higher flow rate | Lower flow rate |
| Space Requirement | Larger space needed | Small space requirement |
| Maintenance | May require cleaning and washing | Easier to replace |
| Cost | Low initial, high maintenance costs | High initial, low maintenance cost |
| Longevity | Lasts up to six years | Maximum service life of four years |
| Carbon Footprint | High carbon footprint | Low carbon footprint |
To make the comparison clearer, let’s break down the advantages and disadvantages of bag filters and cartridge filters.
Bag Filters
Advantages:
- Bag filters are well-suited for applications with heavier dust loads, like saw mills or cement production facilities, as baghouse dust collectors use higher flow rates.
- These bag filters can also handle larger or more abrasive dust particles like sawdust, since the materials used to create the filters are designed for the task.
- Baghouse dust collectors and bag filters require a lower investment to procure and set up, as material and production costs are more affordable.
- Bag filters can last up to six years before replacement, further reducing operational costs.
- Bag filters can utilize a pre-coating layer (e.g., lime or activated carbon) to improve filtration efficiency for sticky or fine particles. Over time, retained dust forms a “filter cake” that enhances particle capture without significantly increasing pressure drop.
- Bag filters can be equipped with antistatic or flame retardant materials to reduce the risk of explosion in industries that handle combustible dust (e.g., woodworking, grain processing).
Disadvantages:
- Baghouse dust collectors are typically large, thus requiring a dedicated space in the facility to set up. It may not be ideal for facilities with limited space.
- Since bag filters use higher flow rates, they consume more power and produce a higher carbon footprint.
- Despite the setup requiring a low initial cost, the combination of high power consumption and maintenance costs can rack up the bill in the long term.
- It also takes extra time to clean and wash the filters between uses, which may slow down the production timeline of a facility.
Cartridge Filter
Advantages:
- Cartridge filters have higher filtration capabilities and can process finer particles. Some cartridge filters can even capture bacteria, making them great for industries where cross-contamination must be maintained and dust-free workshops are the norm.
- Thanks to the compact design of cartridge filters, a cartridge dust collector setup will consume less space in a facility compared to bag filters. Moreover, it also cuts the installation and replacement of cartridge filters quickly and easily.
- Cartridge filters can be customized with specialized media (e.g., activated carbon for VOC absorption, PTFE membranes for hydrophobic applications, or HEPA-grade pleated media for submicron particles). This versatility makes them suitable for industries ranging from oil refining to semiconductor cleanrooms.
- Cartridge dust collectors consume less power to continuously operate, reducing energy costs and helping minimize the facility’s carbon footprint.
- Cartridge filters can be constructed of stainless steel, ceramic, or chemically resistant polymers to handle corrosive gases (e.g., chlorine) or high temperature exhaust (up to 400°C/750°F in sintered metal cartridges) critical in chemical plants or foundries.
- Modern cartridge systems can integrate IoT sensors to monitor pressure drop, particulate load, and filter condition in real time, enabling predictive maintenance and avoiding unplanned shutdowns.
Disadvantages:
- As cartridge filters deal with finer particles, these aren’t suited for facilities that produce large dust particles.
- Cartridge dust collectors won’t work efficiently in high flow rate situations, as they require low air flows to properly filter smaller dust particles.
- The initial cost for cartridge filters is steeper compared to bag filters, not to mention the replacement cartridges needed as the facility continues to use the setup.
- Additionally, cartridge filters last only for four years maximum, meaning more frequent replacements and expenses for replacement filters.
With their distinctions, strengths, and weaknesses properly laid out, you might be wondering why we’re talking about these points. Simply put, you’ll need all these details when selecting a filtration setup for your industry or facility’s dust collection system. Which leads us to…
How to Choose the Right Filter for Your Dust Collection System
There are numerous points of consideration when choosing a filter, which mostly rely on the specific industry. However, to make the selection process easier, we’ve narrowed the options to four key points that will determine whether a bag filter or a cartridge filter will suit your needs.
Dust Type
One of the most important factors to consider when choosing between a bag filter and a cartridge filter is the type of dust the facility is dealing with. Since each filter works best with a certain dust type, picking the wrong one may prove costly in time and money.
Larger, more abrasive dust particles or high dust volume facilities should opt for bag filters to properly manage the air purity. Conversely, workshops that produce finer dust particles should use cartridge filters to achieve 100% dust-free requirements.
Application
Next, consider the intended application of the dust collector system when shopping for a dust filter. Depending on the industry it will be used in, a dust filter will prove more useful than the other.
Bag filters work best for industries that produce large volumes of abrasive or corrosive dust, like woodworking facilities or cement plants. The combination of high flow rates and the durability of the filter media ensures that the dust generated will be contained and clean air will circulate.
On the opposite end, cartridge filters are ideal for industries that pay close attention to fine dust particles. Where cleanliness and dust-free environments are of the utmost importance, like pharmaceutical and food processing plants, a cartridge filter is a must-have.
Available Space
Then there’s space to factor into the equation. Not all facilities have the same space allocation to devote to a dust collection system, and spending to secure a dedicated space won’t be practical as well.
As such, you’ll have to mind the size of the dust collection system before securing one. Bag filters, for one, tend to require a large space to set up the filters. That being said, it won’t be ideal for facilities with tight floor areas.
Budget
Last but certainly not least in the consideration list is the budget for procuring the dust filters. Opting for a cartridge filter may suit the facility’s space and dust requirements, but it will also require a significant investment to begin. Replacement will also cost more compared to bag filters, though maintenance will be easier.
Bag Filter or Cartridge Filter: The Call is Yours
Bag filters and cartridge filters are two peas in a pod: they share a basic function of trapping dust particles from the air. Yet while they do the same task, they work better on certain setups.
Bag filters for baghouse dust collectors are the preferred option for dealing with high volumes of dust particles. They’re also great for handling larger, more abrasive dust or those with corrosive natures. However, bag filters will require a large space for setup.
Cartridge filters, on the other hand, are smaller, compact filtration options that shine in managing finer dust particles. These fit perfectly in facilities where low air flow and dust-free workshops are critical to the business’s success. Though keep in mind that initial costs may be higher for cartridge filters.
For all your dust collection system needs, Tysum is the brand to trust. We’re a seasoned manufacturer of dust collectors and media for bag filters and cartridge filters according to your industry’s standards. From off-the-shelf bag filters to tailor-made cartridge filters, rely on our expertise to deliver stunning results.
Talk to our team today to schedule a free consultation and discover how we can develop the bag filter or cartridge filter for your business.
