The manufacturing industry regularly generates dust particles in its day-to-day operations, be it from sourcing the materials to processing and transporting products. With the potential hazards that dust can bring to the facility’s equipment, the workers, and the environment, it’s critical to properly manage the produced dust.

This article will explore the effects of dust particles and how to control the risks these can cause to the industry.

Hazards & Risks of Dust in Manufacturing

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Unregulated dust particles can pose a serious threat to manufacturing workshops, workers exposed to the dust, and the environment. Proper industrial dust control starts with learning about the dust the facilities produce and exploring the risks they bring.

Explosive Risks

Several types of dust have combustible properties that can be a fire and explosion hazard in manufacturing facilities. When left to accumulate, dust particles can clog up the vents of production equipment and cause them to overheat. This leads to unnecessary downtime and costly machine repair or replacement, affecting profits and order fulfillment.

Aside from equipment issues, accumulated dust can also combust and explode when ignited. Triggers include sparks or flames from the machinery, along with mechanical friction. These explosions can result in losses in workers, equipment, and the facility itself.

Risks to Workers

Workers in manufacturing facilities are constantly exposed to dust, some of which can pose serious health hazards. Dust particles typically enter the worker’s body through inhalation, where the dust enters the person’s lungs and results in various respiratory issues.

Some symptoms of harmful dust exposure include coughing, shortness of breath, and nasal irritation. In serious cases, or when exposed to dust with heavy metals or toxic chemicals, this can lead to lung infections and diseases like lung cancer and upper respiratory tract infections. If workers have sensitivities to certain materials, inhaling or skin contact with dust can trigger allergic reactions.

Toxicity

Dust generated by manufacturing facilities can not only be harmful to workshops and workers, but it can also endanger the environment. Most material dust may contain dangerous components like silica and various metals.

Governing bodies like the Environmental Protection Agency set proper guidelines to regulate the spread of dangerous dust in nature. Some of these regulations include efficient air filtration to remove potential pollutants and monitoring of emissions in factories that work with metal products.

Types of Dust in Manufacturing

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There are different types of dust generated in manufacturing, most of which vary depending on the industry and products produced. In this section, we will go through some of the most common, their source, and the potential risks they present when left unchecked.

1. Wood Dust

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Wood dust, also known as sawdust, occurs in every stage of wood processing and is present in wood production facilities. From sawing tree logs into more manageable pieces to sanding the wood to bring out their intricate designs and everything in between, expect wood dust in the workshop. As sawdust is lightweight, it can spread easily in the air if there is no proper dust collector setup.

Risk:

For workers, symptoms of sawdust exposure include irritation of the eyes, nose, and throat, dry throat, and shortness of breath. Extended exposure can lead to lung capacity reduction resulting in occupational asthma and allergic reactions.

For machinery, sawdust can collect on the vents and gaps within the facility equipment, restricting airflow and causing overheating. This also poses a major fire hazard, as sawdust is highly combustible.

2. Silica Dust

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Silica dust is a common dust particle found in mines, tunnels, and quarries. Procuring, processing, and transporting rocks that contain silica causes the dust particles to spread out in the area. Although there are several forms of dust, quartz silica dust found in many rocks and soil is the most dangerous to humans.

Risk:

Workers in construction, stone fabrication, mining, and ceramics production are the most at risk for silica dust exposure. Lack of proper protection and dust removal equipment can cause exposure to silica dust, with breathing difficulties and silicosis, a form of lung disease, being the usual symptoms. Inhaling silica dust for longer periods can lead to chronic pulmonary obstructive disease (COPD), tuberculosis, and kidney problems.

3. Asbestos dust

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Asbestos is a mineral composed of soft, flexible, heat-resistant fiber and is a natural mineral found in certain types of rocks. It comes in three forms: brown asbestos or amosite, blue asbestos or crocidolite, and white asbestos or chrysotile. Asbestos dust occurs when the mineral is processed to create various products.

Risk:

This type of dust can be very dangerous to the health of workers in manufacturing plants, with exposure to even small amounts, can lead to death. When inhaled, the fibers within the asbestos dust will settle in the person’s lungs, which can lead to certain types of cancer.

Asbestosis is another illness caused by inhaling asbestos fibers, a chronic lung disease that inflames and scars the lungs. Symptoms include coughing, wheezing, chest tightness, rapid weight loss, chest pain, and coughing up blood.

4. Plaster or Gypsum Dust

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A common mineral found in lake and sea water deposits, volcanic vapors, and hot springs; gypsum sees great use in the production of construction materials, paper, and textiles. From plaster to ceiling times, gypsum is usually added to make the mixture set quicker and help control setting times. Gypsum dust occurs in two main points: the procurement of gypsum and the mixing of the material in production plants.

Risk:

Understanding these risks helps clarify the contexts where gypsum may be hazardous, reinforcing the need for preventive measures, such as protective equipment and regular monitoring, particularly in occupational and environmental settings.

While a generally safe material, continuous exposure to gypsum dust can lead to occupational hazards in the workplace, more so if it contains silica. Inhaling gypsum dust can irritate the lungs and decrease its functionality, with pneumoconiosis possible if silica is present in the dust. Additionally, it can also cause neurological conditions like muscle numbness and joint pain.

5. Metalliferous dust

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Manufacturing and mining sites that produce metals like tin, iron ore, nickel, zinc, gold, silver, and copper generate large volumes of metalliferous dust. The dust can be seen in both the surface and underground sections of the facility and is produced while extracting, gathering, processing, and stocking these minerals.

Risk:

Workers who inhale dust particles from metalliferous ores can experience respiratory problems, especially with prolonged exposure. These particles can also enter the bloodstream, affecting the person’s organs and body tissues, with the lungs becoming their primary target. Additionally, some minerals released through the process like copper and zinc can cause serious damage to the human body.

6. Coal dust

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Coal dust is a byproduct found in coal mining and manufacturing facilities. This type of dust usually occurs in several stages of the coal production and storage process. From mining the coal and loading it for transportation to pulverizing and stocking the product, coal dust is generated and lingers in the air.

Risk:

Coal dust is another material dangerous for miners to inhale. Exposure leads to several body problems. Prolonged exposure to coal dust leads to coal worker’s pneumoconiosis or black lung disease, an illness that mainly hits the lungs. Symptoms of black lung disease include chest tightness, black mucus on cough, and shortness of breath.

Tips for Efficient Dust Control in Manufacturing

In the previous section, we discussed the sources and potential risks that allowing dust to roam the facilities. This time, we will look at practical ways to manage dust in the workplace to protect the workers and equipment.

1. Understand your workshop dust

Effective dust control in the manufacturing field starts with knowing what dust the facility is generating. This will help the management select the proper dust control equipment for the task and properly protect the facility workers.

Additionally, part of this process is knowing the properties of the materials your facility is working on. It’s important to remember that certain materials produce different types of dust, thus classifying the dust particles generated is critical for successful dust management.

Have the dust analyzed through a reliable testing facility and use the results as a guide in setting up dust collection and prevention protocols. Some factors in dust analysis include particle size, moisture level, composition, and abrasiveness. The more dangerous the dust is, the higher the facility’s safety and management protocols should be.

2. Reduce dust generation at its source

One of the best practices in industrial dust control involves capturing as much dust as close to the source as possible. Dust is generally lightweight, so it can easily float in the facility’s atmosphere once generated, causing harm to the workers and equipment.

Understanding this, it’s vital to push the airborne dust into the dust collector immediately to avoid inhalation or entering the machines. This can be done through a machine connection point or suction mechanisms connected to workshop vents.  

3. Increase ventilation in the workshop

Stagnant air is another main factor in the accumulation of dust particles in manufacturing facilities. When dust particles combine with the factory’s stagnant air, it results in contaminated air that can be harmful when inhaled by the workers.

As such, workshops must have proper ventilation installed to encourage airflow and push contaminated air out of the workshop. Removing unused flat surfaces within the workshop will also help in reducing the accumulation of dust since this gives more room for air to flow.

4. Secure physical means to control the dust in the workshop

Mitigate dust propagation in workshops by utilizing tools that do the job without creating dust. Some options include nail guns and concrete fasteners that use force to attach parts, resulting in dust-free production.

Water dampens dust particles, making them heavier and inhibiting them from rising in the air. So, to control dust on production floors, workers can spray water on surfaces or use water suppression systems.

Additionally, facilities can also use chemicals to control the dust from spreading within the facility. The market offers an assortment of chemical compounds and synthetic polymers for this task. For greener alternatives, lignosulfonate wood derivatives also work in managing dust propagation.

Following our first point, be sure to have proper tools on hand that match the material to be processed. This will help minimize unnecessary dust generation, as these are specifically designed to handle specific materials.

5. Standardize workshop and warehouse workflow

Establishing a standard workflow within a workshop helps mitigate the creation and spread of dust in the facility. It’s recommended to study the current procedures, see key struggles where dust is usually generated, and streamline the process to address key concerns.

This also involves researching other ways to perform a task efficiently while generating minimal dust particles. Less dust produced equals less dust to manage and control, saving time and money as well as maintaining worker health.

Workers should also be informed and trained with the latest workplace standards in dust prevention and control. As they’re regularly prone to dust exposure, facility workers must know how to deal with the dust to avoid health hazards. Moreover, facility managers must monitor the practice of preventive measures and ensure they’re properly implemented within the production site.

6. Regular Cleaning

Performing routine cleaning and maintenance on the equipment and workshop helps remove dust and keep the air dust-free. Production equipment must be cleaned at least once a day, especially in workshops that generate high volumes of dust. Moreover, it’s ideal to have the equipment undergo preventive maintenance to eliminate the particles that could have accumulated inside the machines.

However, cleaning is not only limited to the production machinery but also the ventilation and dust collection setup. Dust collectors should be frequently cleaned to clear out the dust that’s trapped along with routinely replacing the filters with fresh ones.

7. Personal protective equipment (PPE)

Personal protective equipment or PPE offers workers the proper protection against the dust particles they encounter on a daily basis. Workers should know how to properly wear and utilize them in order to maximize their effectiveness.

A complete PPE for dust-prone locations must include:

• Breathing devices like respirators capture and filter the air the workers breathe, ideal for dust-heavy worksites. Different dust particles require different types of respirators, so it’s important to study which dust the facility produces.
• Dust masks are the simpler form of respirators, providing limited protection from dust particles, and are preferred for workshops that produce low levels of dust.
• Goggles and other eye protection equipment prevent dust particles from affecting the worker’s eyes. This also keeps vision clear and unclouded in workshops when dust accumulates.
• Gloves allow workers to handle equipment and materials in dust-laden environments while preventing skin irritation and cleanliness.
• Full-body suits cover the worker’s whole body and are their best friend in dusty workshops. These are typically made from non-woven fiber, making sure that dust particles won’t stick to the suit.

8. Be familiar with local and national regulation guidelines

Depending on where the facility is located, there are regulating bodies that impose strict guidelines that protect the production site, its workers, and the surrounding area. They will also typically have set rules for dust management and control, which facilities should follow to avoid fines and potential closure.

In the United States, the four main organizations are the following:

Occupational Safety and Health Administration or OSHA

This organization emphasizes workplace safety, setting up standards regarding dust prevention and control. Part of their guidelines include maintaining a safe working environment, recognizing harmful dust in workshops, and regulating permissible exposure limits for these hazardous dust particles.

National Fire Prevention Association or NFPA

As an international organization, the NFPA commits to protecting human life and properties from hazards related to fire and electricity, among other things. One of their regulations is the NFPA 652, a standard referring to combustible dust particles.

This regulation requires manufacturing facilities to conduct a dust hazard analysis to know more about the dust particles generated. It also demands facilities to have the proper dust collection systems with safety controls.

Food and Drug Administration or FDA

The FDA mainly handles dust regulations for food and pharmaceutical production, particularly setting standards to avoid contamination and employee protection. They set standards on processing, sanitation practices, food allergens, and supply chain management. Additionally, they also provide instructions on how manufacturers should handle a recall plan in case of cross-contamination.

Environmental Protection Agency or EPA

While other governing bodies focus on the manufacturing facility and the workers, the EPA is more involved in environmental protection. In particular, they set rules for dust collection and emissions released by production plants. Their National Emission Standards for Hazardous Air Pollutants (NESHAP) Rule 6X regulates the proper filtration of hazardous air pollutants in metal fabrication.

Selecting a Dust Collection System for Your Factory

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Choosing the right dust collection system in a manufacturing facility greatly improves the control and removal of harmful dust particles. But how should one determine which dust collector will work best in their facility? We’ve prepared a couple of tips on selecting the ideal dust removal machinery.

Determine the Dust Type and Composition

The first factor to consider is the type of dust that needs to be collected.

As we’ve discussed in previous sections, dust particles may have different compositions and characteristics. Depending on the dust type generated, the facility will require specific dust filtration setups. Major considerations for classifying dust types include their size, texture, toxicity levels, concentration, and moisture levels.

Additionally, dust types have three risk classes, namely low-risk, medium-risk, and high-risk. Each risk class has an allowable maximum concentration level, which will factor in when selecting the industrial dust removal equipment to be used.

Then there’s how combustible the dust is to consider, referring to how quickly the dust will catch fire when triggered. Highly combustible dust particles need to be removed from the air as soon as possible to avoid risking the equipment and workers.

Base Dust Collector Capacity on Facility Size and Setup

Next on the list in the dust collection system selection process is checking the dimensions of the manufacturing facility. Various dust collectors have different suction capacities; thus, the workshop’s size will be vital in choosing the right one. Dust removal setups work better for larger workshops, while smaller and standalone dust collectors are ideal for tighter workspaces.

Moreover, the facility’s layout also determines which dust collection system should be installed. Existing vents and air ducts within the facility can be utilized for dust collection, saving on installation costs and time. For older facilities without existing ventilation systems, additional revisions may be needed to maximize the dust removal machinery.

Tysum – Your Partner in Warehouse Dust Control

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For reliable and powerful warehouse dust collection solutions, Tysum is the brand to trust. As a renowned maker of dust collectors in China for two decades and counting, our market expertise and unparalleled skill create the right machinery for your industry needs.

We offer a selection of dust collection systems and filtering media designed to handle various types of dust with precision and efficiency. With our dust collectors installed in your facility, you can be confident that even the tiniest dust particles are cleared from the air, preventing any risk to the workers and equipment. Plus, we can develop custom air filtration equipment based on your facility’s specific requirements.

Complementing our time-tested dust collector production is an intensive quality control and testing process. Our team of seasoned auditors conducts meticulous inspections in every production step, ensuring you receive the best dust collectors and filtration media. We also guarantee that our equipment meets local and international standards, as each test follows strict regulations.

Going beyond traditional product making, Tysum provides comprehensive services to make your sourcing experience smooth and seamless. From design customization and seamless overseas shipping to responsive aftersales support, we’re here to improve the air quality of manufacturing facilities in any way possible.

Keep Manufacturing Facilities Clean with Dust-Free with Industrial Dust Collection

Managing dust hazards in factories and worksites is an important aspect of maintaining a manufacturing business, more so when it generates high volumes of dust particles. Dust particles can pose a serious concern for both the workers and the equipment used, leading to lower production, unwanted expenses, and reduced workforce. As such, these facilities should have efficient dust control systems and practices to filter the air and protect the employees and other investments.

Choosing the ideal dust filtration system involves several factors, including knowing the type of dust and considering the facility setup. Moreover, implementing practical dust control protocols results in a dust-free and safe workplace.