Dust Collection Engineering & Custom System Design
Every system we engineer is designed to meet OSHA 29 CFR 1910.94 and NFPA 660 requirements — backed by our pass-or-free guarantee.
Our dust collection engineering team designs custom air filtration systems built around your specific operation — not off-the-shelf catalog picks. We start with your process, your materials, and your facility layout, then work backward to the right equipment, ductwork, and controls.
Every system we deliver includes complete compliance documentation for OSHA 29 CFR 1910.94 and NFPA 660 — and it’s all backed by our pass-or-free compliance guarantee. Your system passes inspection, or we fix it at no cost.
Not sure what you need yet? That’s exactly what our free site assessment is for. We come to your facility, evaluate your operation, and give you a straight answer on what it’ll take to get compliant — no obligation. Get started here →
How We Engineer Your Dust Collection System
Every project follows the same rigorous four-step process — whether it’s a single welding cell or a plant-wide system serving dozens of pickup points.
Site Assessment & Process Analysis
We begin every dust collection engineering project with a comprehensive on-site evaluation to understand your operation — material types, generation rates, particle size distribution, temperature, humidity, and space constraints.
We also evaluate existing infrastructure (electrical capacity, compressed air), production schedules, and regulatory requirements including OSHA PEL/TLV limits and NFPA 660 combustible dust standards. Many of the most expensive problems we uncover at this stage are entirely preventable — our guide to common dust collection design mistakes covers the ones we see most often.
If your dust is potentially combustible, we coordinate dust hazard analysis (DHA) testing as part of this phase to determine Kst values and explosion severity before any design work begins.
Engineering Calculations & System Sizing
Using industry-standard methodologies and specialized software, we calculate airflow requirements (capture velocities, transport velocities, ACFM/SCFM), static pressure analysis, fan selection, filter sizing and media selection, ductwork design, and energy consumption projections.
Undersized systems are one of the most common — and most expensive — mistakes in this industry. If you’re evaluating an existing system, our guide to 5 signs your dust collector is undersized shows exactly what to look for. For a full breakdown of new system costs, see our 2026 dust collection cost guide.
3D CAD Design & Layout
We create detailed three-dimensional models showing equipment placement, clearance verification for ongoing maintenance access, integration with existing equipment, installation details including support structures, and safety features like platforms, ladders, handrails, and explosion venting. Ductwork layout is designed and specified at this stage — for a complete picture of what that entails, see our industrial ductwork guide.
Deciding whether to recirculate air or exhaust outside? That decision gets made here — it has real cost and compliance implications we work through with you before design is finalized.
Compliance Documentation & Turnkey Delivery
We ensure your system meets all applicable regulations: OSHA 29 CFR 1910.94 ventilation requirements, NFPA 660 combustible dust standards, EPA air quality permits, local building codes, and insurance carrier requirements.
Every system we deliver is backed by our pass-or-free compliance guarantee. If it doesn’t pass inspection, we fix it at no charge.
Advanced Dust Collection Engineering Capabilities
CFD Airflow Modeling
Computational Fluid Dynamics analysis to optimize hood design, predict capture efficiency, and identify problematic airflow patterns before installation. Especially critical for complex welding and metal fabrication layouts with multiple pickup points.
Explosion Modeling
Advanced explosion venting calculations using Kst values and empirical data to properly size deflagration vents and suppression systems per NFPA 68.
Energy Analysis
Life-cycle cost analysis comparing equipment options, VFD controls, and heat recovery to minimize long-term operating expenses. Understand the true cost of ownership before you commit.
Noise Reduction
Acoustic engineering to reduce sound levels through silencer selection, equipment placement, and sound attenuation strategies — keeping your facility under OSHA’s 85 dBA action level.
Structural Engineering
Coordination with structural engineers for roof-mounted equipment, floor loading analysis, and seismic design requirements. Particularly important for outdoor baghouse installations in our Southwest service area.
Controls Integration
Integration with facility BMS, PLC programming, remote monitoring systems, and IoT sensor packages for real-time differential pressure and airflow tracking.
Dust Collection Engineering Across All System Types
We don’t push one collector type for every application. Our engineering starts with your process and works backward to the right equipment.
Baghouse & Fabric Collectors
Reverse air, shaker, pulse-jet configurations. Filter media selection, cleaning optimization, hopper design. See our baghouse systems →
Cartridge Collectors
Downflow, horizontal, vertical configurations. Cartridge selection, cleaning systems, pre-filtration options. See our cartridge systems →
Wet Collectors
Venturi, packed tower, and spray chamber configurations. Ideal for combustible metals where dry collection isn’t safe. Not sure which is right for your application? See wet collectors vs. dry collectors. See our wet collector systems →
Source Capture Systems
Enclosing hoods, exterior hoods, capture velocity calculations, placement optimization. See our source capture arms →
Downdraft & Booths
Downdraft tables for grinding and sanding, spray booths for coating and finishing operations.
Specialty Applications
Plasma and laser collectors, oil mist systems for CNC, and ambient air cleaners for supplemental filtration.
Industries We Engineer Systems For
Different industries generate different dusts with different hazards. Our dust collection engineering accounts for the specific materials, regulations, and operational requirements in each sector.
Complete Engineering Documentation
Every dust collection engineering project includes comprehensive documentation for installation, permitting, and long-term maintenance.
Design Calculations
Airflow, pressure, fan selection, filter sizing
3D CAD Drawings
Equipment layout, ductwork routing, installation details
Equipment Submittals
Technical specifications, performance data, dimensions
Installation Manual
Step-by-step procedures and requirements
Control Schematics
Electrical diagrams, wiring schedules, sequence of operation
O&M Manuals
Operating procedures, maintenance schedules, parts lists
Partnering with Architects & Engineers
We work seamlessly with design professionals on new construction and expansion projects, providing early-phase input to ensure air filtration systems are properly integrated into building design. Visit our architect resource center for specification packages and Revit families.
Design-Build Partnership Services
Design development phase technical specifications · Space and utility requirement planning · Equipment room sizing and layout optimization · Roof loading calculations for outdoor installations · Budget-accurate cost estimates at all design phases · Value engineering alternatives · Construction document preparation · RFI response and submittal processing · Construction administration and site observation
Architect & Engineer Support
Direct Line
Looking to partner on installations? Learn about our contractor partner program.
Related Resources
Ready to Engineer Your Custom System?
Tell us about your operation and we’ll put together a custom engineering proposal — including a site visit, system design, and a firm quote backed by our pass-or-free guarantee. No pressure, no runaround.
Serving manufacturing facilities across Arizona, California, Nevada, New Mexico, and Utah.