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Home / Blog / Baghouse Troubleshooting: Problems and Answers

Baghouse Troubleshooting: Problems and Answers

Table of Contents

1. Baghouse Filter Problems
2. Baghouse Filter Troubleshooting: Common Issues
3. Cleaning System Troubleshooting
• Pulse Jet Cleaning Malfunctioning
• Shaker Malfunctioning
• Reverse Air Cleaning Malfunctioning
4. Baghouse Parts

Baghouse Filter Problems

It’s important to conduct regular baghouse troubleshooting to avoid any halts in the production process and any contamination of your premises and the environment. The following are examples of a baghouse emergency that you may encounter:

Baghouse Filter Troubleshooting: Common Issues

Problem #1: There has been a drop in the amount of filtered air.
a) The bags are overfilled with dust. Solution: Clean the bags via one of the following methods: mechanical cleaning, pulse jet cleaning, or shaker method.
b) The hopper is overfilled with dust. Solution: Remove the dust from the hopper.

Problem #2: The velocity of the air passage is too high.
a) The ventilator’s speed is set too high. Solution: check the amps that the fan is set at.
b) The frame of the system is too large. Solution: if it is causing an issue, size down the frame.
c) Incorrect air passage in the system frame. Solution: ensure that everything is duly sealed and that the dampers are properly directing the air.

Problem #3: A large quantity of dust has accumulated at the outlet.
a) The filter bags are damaged. Solution: replace them with new ones.
b) The filter bags aren’t properly installed. Solution: Redo the installation of the filter bags and check that all of the dimensions match up.

Problem #4: There is a large pressure differential of clean and contaminated air.
The filter bag is overfilled with dust. Solution: Clean the bags via one of the following methods: mechanical cleaning, pulse jet cleaning, or shaker method.

Problem #5: The hopper is getting filled up too quickly.
a) Material bridging is taking place. Solution: destroy the bridged material.
b) The unloading mechanism is malfunctioning. Solution: Have a repair done or replace the unloading mechanism.

Problem #6: Moisture is accumulating in the dust collector
a) The temperature inside the baghouse is below the dew point. Solution: Increase the gas temperature and install insulation for the device.
b) Cold connection points. Solution: Use insulation to ensure metal line isn’t causing condensation.
c) The device isn’t sufficiently cleaned after the factory’s processes are powered off. Solution: Keep the device on for an extra ten minutes at the end of your daily operations.

Torch-Air’s baghouses are simple in design and feature high-quality components which ensures ease of installation and servicing along with long-lasting, efficient filtering, rendering little troubleshooting necessary.

Cleaning System Troubleshooting

Pulse Jet Cleaning Malfunctioning

One of the first things you’ll want to consider in pulse jet troubleshooting is that the pressure setting and the dimensions match the instructions. The proper air to material ratio is 6 to 1. If your device is smaller than that, you may want to either install a larger device or use pleated bags. Also make sure to check the compressed air setting, the differential pressure, and leaks. Adjust the pressure setting if need be. Make sure the pulses are set for 0.1 to 0.15 seconds.

Shaker Malfunctioning

First off, check that everything locked in place. See if the fastening elements are tight. Some of these may be in need of repair. Make sure that the cleaning frequency is on point as well.

Reverse Air Cleaning Malfunctioning

There are a few details to start off checking when it comes to reverse air dust collector troubleshooting. Check the proper functioning of your damper valves, differential pressure, the correct level of tension, the direction in which your reverse air fan is spinning, and that you have at least a 3 to 1 air to material ratio. If you have parts malfunctioning, you may need to repair them. Particularly important is that you have sufficient air volume.

Baghouse Parts

Filter bags

A common issue and one of the most obvious places to start with dust collector troubleshooting can be checked via the eye test. Bags often develop tears, holes, and air, gas, or dirt bleeding. These can be caused by a number of issues. When this happens, the filter bags will need to be replaced entirely.
Baghouse Diagram
Baghouse Diagram

Air to cloth ratio

This should be at least 3 to 1. If your system is too large, it will need more cleaning power, but if it’s not big enough, your filter bags won’t last.

Poor installation

If the device isn’t installed properly, certain parts of filter bags will be disproportionately affected. Cleaning frequency: cleaning too often will cause excess wear while not cleaning often enough can leave dirt sticking around. Make sure you strictly follow the instructed schedule.

Air Compressor

Ensure that the air compressor is on and supplying sufficient energy.

Fan Troubleshooting

Insufficient or excess velocity: Check that your ventilator is set to the proper number of amps. If so, you’ll want to check the electrical connections and wiring are connected to the correct terminals. Make sure that the ventilator is spinning in the right direction as well.

Valves, Dampers, Elbows, and Sealing

Valves and dampers can malfunction as well. Ensure that the air is being properly directed. You’ll want to check that there is proper sealing.

The route or elbows may be an issue as well. If so, you will need to redesign the air route to allow for the right speed. Remember that there can also be leakage between the dirty and clean air compartments. These can be repaired using caulk or welding.

Also make sure that nothing is blocking the outlet.


Ensure that these are properly installed and aren’t subjected to disproportionate wear.

Pressure Sensors, Gauges, and Timer

Troubleshooting includes each individual measurement device being checked as well.


With hoppers, it’s rather simple. If the hopper isn’t emptied often enough or bridging is present, this will cause excess wear on the filter bags.

Heater Troubleshooting

Make sure these are working properly. If there is too much heating in the filter bags, there is a risk of burning while if there isn’t enough and certain areas of the filter bag are left cold, this paves the way for condensation which can cause dirt to cake and thus plug the filter bags, which is then hard for the cleaning system to remove.

If the filter bag is below the dew point, you will need better insulation for the machine.

Baghouse troubleshooting is usually not too difficult to perform. If you don’t find the necessary baghouse problems and answers in this guide, you may need your devices checked by a professional.
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