Combustible Dust in the Composite Industry
Understanding the Risks and Solutions for a Safer Facility
Hazards of Combustible Dust in the Composite Industry
Is Composite Dust Combustible?
Many types of composite dust are highly combustible, posing serious fire and explosion risks. Fiberglass, carbon fiber, resins, and other powdered materials commonly found in composite manufacturing can become hazardous when suspended in the air. The level of risk depends on factors such as particle size, concentration, and ignition sources within the facility.
Are There Any Examples of Combustion Events Stemming from Composite Dust?
Combustible dust explosions in composite facilities have resulted in significant property damage, injuries, and fatalities. Notable incidents include plant explosions caused by accumulated resin dust or finely powdered composite materials igniting due to static discharge or overheating equipment. These tragedies highlight the importance of dust control measures in composite processing plants.
What is the Best Way to Manage Combustible Dust?
SonicAire Dust Control Fans: A Proactive Solution
SonicAire utilizes precision dust-control technology, which is engineered specifically for the composite sector. SonicAire’s industrial control fans proactively prevent combustible dust build-up, thereby maintaining a clean and safe environment in a cost-effective manner. SonicAire’s proprietary technology combines high-velocity airflow and thermal current control to regulate dust flow.
SonicAire Dust Control Fans simplify fugitive dust management through a structured process. First, key dust control challenges are identified. Next, a customized engineered system is designed for the specific facility and the type(s) of dust it produces. Then, the fans are delivered and can be installed by SonicAire, facility personnel, or a qualified contractor. Finally, the result is reliable, automated protection against future dust accumulation.
How Does SonicAire Prevent Dust Accumulation?
SonicAire Uses High-Velocity Airflow to Disrupt Dust Accumulation
SonicAire industrial fans utilize high-velocity airflow to control and manage airborne dust before it can settle. By creating continuous movement, these fans prevent the accumulation of combustible dust on overhead structures, thereby reducing the likelihood of hazardous levels being reached.
Additionally, SonicAire Uses Thermal-Current Control Using BarrierAire™ Technology
SonicAire fans incorporate BarrierAire™ technology, disrupting rising thermal currents that can carry fugitive dust into dangerous, hard-to-reach areas. BarrierAire™ is a special kind of air control technology used in SonicAire dust control fans. Think of it like an invisible shield of air that stops dust from rising up into the rafters and overhead areas of your plant. As the fan moves the air, it causes agglomeration. That means tiny dust pieces stick together and form bigger clumps (called agglomerates).
As these dust clumps grow larger and heavier, they fall to the floor.
So instead of dust floating around in the air, or landing up on your pipes and beams where it’s hard to clean, it just ends up on the floor where it’s easy to sweep up.
How SonicAire Can Reduce Overtime and Maintain Compliance in a Composite Industry Facility
Manual Cleaning is Slow and Disrupts Production
Manual cleaning requires downtime, forcing production to halt. The process is slow and dangerous for workers cleaning high-risk overhead areas. This inefficiency costs more than most facility managers realize.
Relying on Expert Cleaning Services is a Costly Cycle
Hiring specialized crews to remove accumulated dust is an ongoing, expensive process. The costs of routine cleanings add up, yet dust accumulates immediately after cleaning is completed.
Case Study: Proactive Dust Control in a Composite Facility
Viking Yachts, a composite fabrication plant in the boat-building industry, implemented SonicAire fans and saw:
Reduced cost
Before having SonicAire fans, the company would outsource cleaning once the buildup was noticeable.
“It took crews five months to work through the facility. In addition, cleaning once the dust has already accumulated is not the most effective management strategy. SonicAire has developed a product that can reduce the frequency of cleaning or, in some cases, prevent the dust from ever accumulating.”
Reduced downtime
Manual housekeeping of high surface areas was highly disruptive to production. Even with crews working nights, significant time was allocated to moving parts and molds to provide access.
Reduced risk
“There are a lot of variables that contribute to combustible dust events, but if you can find a way to control one or more of those contributing factors, you can reduce the risk of an event. Managing the dust accumulation levels is one way to reduce that risk—and the SonicAire fans are a good tool to do that.”
Increased morale
“Employees like the idea that their work areas are safer and ultimately cleaner.”
Increased compliance
“Staub (Special Projects Manager) notes that managing dust accumulation with SonicAire fans allows Viking Yachts to better comply with the requirements of state fire codes.”
A New Standard for Dust
NFPA Standard 660: The Final Word on Combustible Dust
In late 2024, NFPA published Standard 660, setting the benchmark for combustible dust safety. This comprehensive regulation ensures uniform compliance across all industries handling combustible dust.
NFPA 660 combines several previous standards into one, making it easier for facilities to understand and follow best practices. With more straightforward guidelines and stricter enforcement set by the NFPA, proactive dust control solutions like SonicAire fans have become even more crucial for compliance.
It’s noteworthy that SonicAire’s COO serves on the NFPA Fundamentals of Combustible Dusts Committee, actively participating in the development and maintenance of these crucial industry standards.
The SonicAire Compliance Guarantee
We’re so confident in our products’ ability to solve your problems that we now offer the SonicAire Compliance Guarantee*.
As long as SonicAire fans are correctly installed and maintained according to our engineers’ layout/engineering recommendations, they will eliminate the need for housekeeping in hard-to-reach overhead spaces.
And if they don’t, we’ll provide a full refund on the cost of fans or reimburse the cost of any imposed fine, whichever is less.
Click here to read the full SonicAire Compliance Guarantee.
Additional Resources
SonicAire fans are the only proactive solution designed to eliminate the hidden dangers of combustible composite dust. Protect your facility, workforce, and bottom line with industry-leading dust control technology.
