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Frequently Asked Questions

Check below for frequently asked questions regarding SonicAire fans.

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Frequently Asked Questions

Do SonicAire fans continue to blow dust all around the facility?

In short, no. SonicAire fans create a barrier, or a horizontal curtain of air that keeps the dust from making a free trip to the ceiling via rising warm air currents. The air in your facility will actually have less free-floating particulate in it than it did before you had SonicAire fans installed.

Check out our white paper on Dynamic Particle Control for more information.

There’s no one answer to this question, as there are many, many different types of dust, even at different points along a single process. Additionally, the layout and machinery used in each facility is different. Our sales and engineering team will determine what fan type works best in your facility with your dust and processes.

SonicAire fans improve air quality. They make for happier employees, and more importantly, safer employees. Check out the air quality study we did in a PVC blending/composite lumber facility in the Dynamic Particle Control white paper.

SonicAire fans robotically reduce fugitive dust accumulation. High-velocity, high-mass airflow from our fans creates an overhead barrier. Our BarrierAire™ technology forces dust to the floor by preventing upward currents and stagnant air that keeps dust in suspension, preventing accumulation of fugitive dust in overhead and hard-to-reach places. All you have to do is sweep it up off the floor!

The type (size, weight, moisture-content, etc.) of dust you make will determine how many fans you’ll need. Facilities can use $2.50 per square foot as a budgetary figure for an installed system. The specific cost for your facility can be determined once our engineers fully understand your particular situation.

The number of fans required is based on a number of factors including the size of the dust producing area as well as the type and quantity of dust produced. Our team can create an engineered solution for your facility to ensure minimal dust buildup in overhead spaces. Click here to request your Free Dust Management Plan with ROI Analysis.

Yes! SonicAire offers full-service installation, including mechanical setup, electrical wiring, and system startup/commissioning. They’ll manage the entire process or work alongside your preferred contractors. Whether you require full installation, partial support, or just guidance, SonicAire offers flexible options to suit your needs—and all completed installations include an additional one-year warranty.

Grain dust is highly volatile because of its low Minimum Ignition Energy (MIE), low Minimum Explosive Concentration (MEC), and the way it’s handled in facilities—especially at transfer points where fine, dry “fugitive dust” escapes and collects. These factors make it easy for grain dust to ignite and cause explosions, which is why proper dust control and housekeeping are essential in food and grain environments.
Some SonicAire fans are! While SonicAire fans are not rated for Class I (gas/vapor) hazardous locations, they do offer models that are UL certified for Class II hazardous locations, where combustible dust is present. This includes both Division 2 (dust present under abnormal conditions) and now also Division 1 (dust present under normal conditions). These Class II-certified fans can also be used in Class III environments involving ignitable fibers or flyings.
The key is compliance—especially with dust-related standards. SonicAire fan systems help you stay inspection-ready by preventing the buildup of combustible dust in overhead spaces. When installed and operated as directed, they come with a compliance guarantee that ensures your overhead areas meet NFPA 652 standards. That means less stress when the fire marshal, insurance inspector, or corporate auditor shows up.
Nope! SonicAire fans don’t stir up dust—they stop it from ever reaching overhead spaces. Using a patented technology called BarrierAire™, the fans disrupt thermal currents and utilize agglomeration (where dust particles stick together like Velcro) to make airborne dust too heavy to remain suspended. The result? Cleaner overhead surfaces and improved air quality throughout your facility—without creating clouds of airborne dust.
A Dust Hazard Analysis (DHA) is a critical safety review that identifies and addresses combustible dust risks in your facility, as required by NFPA 652 and NFPA 660. If your plant creates or handles dust, you likely need a DHA—starting with a lab test to determine if your dust is combustible. If it is, a qualified team must document hazards, safeguards, and action plans. Fire marshals, OSHA, and insurance providers may ask to see your DHA, so having one protects both your people and your liability

There are five key electrical considerations to plan for before installing a SonicAire system:
1. Motor Control Center (MCC): 3-phase power (208–575V) and ~50 amps are needed.
2. Area Classification: Hazardous zones (like Class II Div 1 or 2) impact fan and conduit types.
3. Fan Controls: Choose from simple switches or advanced Command panels with programmable features and fire alarm interlock.
4. Local Disconnect Switches (LDS): Required for each fan and can be mounted at various locations—installation method affects convenience and cost.
5. Zone Controls: Used to prevent airflow disruption to sensitive areas near the fan.
Need help? SonicAire will guide you through the best option for your facility setup.

SonicAire began in 2004 when founder Brad Carr recognized a need for improved dust control, having worked in textile air filtration. What started as a small venture quickly grew when a major tissue manufacturer urgently needed fans to stay OSHA compliant. Through continuous innovation—including industry-first designs like the MobileFlex, AutoSweep, and UL-certified hazardous duty fans—SonicAire has evolved into the leader in combustible dust control. Their fans are engineered not just to move air, but to manage and prevent dust buildup using science-backed technology tailored for real-world industrial challenges.
Dust collection systems are essential—but they’re never 100% effective. Over time, filter performance declines, dust escapes through imperfect capture points, and changes in production can impact ductwork efficiency. Thermal air currents lift fugitive dust that escapes and settles in hard-to-reach overhead spaces. SonicAire fans serve as a second line of defense, creating an air barrier that prevents dust from accumulating above. The result? Cleaner ceilings, fewer shutdowns, and easier, more compliant inspections.
The number of fans you need depends on your dust type, facility layout, and the fan model. On average, one fan can cover around 7,000 square feet, with a performance range of 2,000 to 11,000 square feet, depending on your environment. Fan placement also considers process type, ceiling structures, moisture content, and air currents. For the most accurate system design, SonicAire offers a custom engineering process tailored to your unique facility and dust conditions.
Yes! SonicAire offers full-service installation, including mechanical setup, electrical wiring, and system startup/commissioning. They’ll manage the entire process or work alongside your preferred contractors. Whether you require full installation, partial support, or just guidance, SonicAire offers flexible options to suit your needs—and all completed installations include an additional one-year warranty.
Grain dust is highly volatile because of its low Minimum Ignition Energy (MIE), low Minimum Explosive Concentration (MEC), and the way it’s handled in facilities—especially at transfer points where fine, dry “fugitive dust” escapes and collects. These factors make it easy for grain dust to ignite and cause explosions, which is why proper dust control and housekeeping are essential in food and grain environments.
Some SonicAire fans are! While SonicAire fans are not rated for Class I (gas/vapor) hazardous locations, they do offer models that are UL certified for Class II hazardous locations, where combustible dust is present. This includes both Division 2 (dust present under abnormal conditions) and now also Division 1 (dust present under normal conditions). These Class II-certified fans can also be used in Class III environments involving ignitable fibers or flyings.
The key is compliance—especially with dust-related standards. SonicAire fan systems help you stay inspection-ready by preventing the buildup of combustible dust in overhead spaces. When installed and operated as directed, they come with a compliance guarantee that ensures your overhead areas meet NFPA 652 standards. That means less stress when the fire marshal, insurance inspector, or corporate auditor shows up.
Nope! SonicAire fans don’t stir up dust—they stop it from ever reaching overhead spaces. Using a patented technology called BarrierAire™, the fans disrupt thermal currents and utilize agglomeration (where dust particles stick together like Velcro) to make airborne dust too heavy to remain suspended. The result? Cleaner overhead surfaces and improved air quality throughout your facility—without creating clouds of airborne dust.
A Dust Hazard Analysis (DHA) is a critical safety review that identifies and addresses combustible dust risks in your facility, as required by NFPA 652 and NFPA 660. If your plant creates or handles dust, you likely need a DHA—starting with a lab test to determine if your dust is combustible. If it is, a qualified team must document hazards, safeguards, and action plans. Fire marshals, OSHA, and insurance providers may ask to see your DHA, so having one protects both your people and your liability.

There are five key electrical considerations to plan for before installing a SonicAire system:

1. Motor Control Center (MCC): 3-phase power (208–575V) and ~50 amps are needed.
2. Area Classification: Hazardous zones (like Class II Div 1 or 2) impact fan and conduit types.
3. Fan Controls: Choose from simple switches or advanced Command panels with programmable features and fire alarm interlock.
4. Local Disconnect Switches (LDS): Required for each fan and can be mounted at various locations—installation method affects convenience and cost.
5. Zone Controls: Used to prevent airflow disruption to sensitive areas near the fan.

Need help? SonicAire will guide you through the best option for your facility setup.

SonicAire began in 2004 when founder Brad Carr recognized a need for improved dust control, having worked in textile air filtration. What started as a small venture quickly grew when a major tissue manufacturer urgently needed fans to stay OSHA compliant. Through continuous innovation—including industry-first designs like the MobileFlex, AutoSweep, and UL-certified hazardous duty fans—SonicAire has evolved into the leader in combustible dust control. Their fans are engineered not just to move air, but to manage and prevent dust buildup using science-backed technology tailored for real-world industrial challenges.

Dust collection systems are essential—but they’re never 100% effective. Over time, filter performance declines, dust escapes through imperfect capture points, and changes in production can impact ductwork efficiency. Thermal air currents lift fugitive dust that escapes and settles in hard-to-reach overhead spaces. SonicAire fans serve as a second line of defense, creating an air barrier that prevents dust from accumulating above. The result? Cleaner ceilings, fewer shutdowns, and easier, more compliant inspections.

The number of fans you need depends on your dust type, facility layout, and the fan model. On average, one fan can cover around 7,000 square feet, with a performance range of 2,000 to 11,000 square feet, depending on your environment. Fan placement also considers process type, ceiling structures, moisture content, and air currents. For the most accurate system design, SonicAire offers a custom engineering process tailored to your unique facility and dust conditions.

TLDR: SonicAire offers a free ROI calculator on their website to determine payback period for dust control fan systems. The calculation considers your dust type, facility size, current cleaning costs, production downtime, and electrical costs. Beyond financial returns, benefits include safety compliance, reduced risk, and a healthier workplace.

TLDR: SonicAire’s four-step process includes: 1) Discovery—understanding your facility and dust challenges, 2) Design—creating a customized solution, 3) Delivery—implementing the system with installation options, and 4) Dust is Done—providing ongoing support with a compliance guarantee.

The number of fans you need depends on your dust type, facility layout, and the fan model. On average, one fan can cover around 7,000 square feet, with a performance range of 2,000 to 11,000 square feet, depending on your environment. Fan placement also considers process type, ceiling structures, moisture content, and air currents. For the most accurate system design, SonicAire offers a custom engineering process tailored to your unique facility and dust conditions.

TLDR: SonicAire fans provide cost-effective dust mitigation through continuous operation that prevents accumulation, reducing downtime and potential regulatory fines. The technology helps maintain compliance, reduces cleaning costs, and creates safer working environments.
TLDR: SonicAire fans offer precise airflow control through the iDrive system (adjustable up/down movement between 35-120 degrees) and optional Zone Control Kits that prevent the fan from blowing in sensitive areas during rotation.
TLDR: SonicAire offers fans certified for Class II Division 1 and Division 2 hazardous locations (combustible dust environments). The company doesn’t offer fans for Class I (flammable gas/vapor) locations but their Class II fans can be used in Class III (ignitable fibers) environments.
TLDR: SonicAire offers multiple installation options: full turnkey installation by their team, mechanical installation with customer handling electrical, installation support/guidance for DIY customers, or just startup/commissioning services. All professional installation options add an extra year of warranty.
TLDR: SonicAire fans should never be made mobile as this creates serious safety hazards: it defeats the proactive design purpose, may create combustible dust clouds, violates safety certifications, and breaks NFPA 660 guidelines requiring continuous operation during processes.
TLDR: A single SonicAire fan typically covers 2,000-11,000 square feet depending on dust type, facility conditions, and fan model. The company recommends professional assessment to determine exact needs rather than using square footage estimates alone.
TLDR: SonicAire fan systems typically cost around $2.50 per square foot installed, though factors like dust type, area classification, temperature/moisture conditions, installation accessibility, and electrical infrastructure can affect final pricing.
TLDR: SonicAire fans complement existing dust collection systems rather than replacing them. While filtration captures dust at the source, fans prevent the escape of “fugitive dust” from settling in overhead spaces, creating a complete dust management solution.
TLDR: Unlike conventional fans, SonicAire fans don’t simply blow dust around. Their BarrierAire technology disrupts thermal currents and uses agglomeration (making particles stick together and become heavier) to prevent dust from reaching overhead.

Compliance

Are SonicAire fans rated for hazardous locations?

SonicAire offers fans certified for Class II Division 1 and Division 2 hazardous locations (combustible dust environments). The company doesn’t offer fans for Class I (flammable gas/vapor) locations but their Class II fans can be used in Class III (ignitable fibers) environments.

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SonicAire fans help simplify fire marshal inspections by guaranteeing compliance with NFPA dust accumulation standards. The fans provide continuous cleaning of overhead spaces, eliminating a common citation issue during safety inspections.

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A Dust Hazard Analysis is an NFPA-required assessment to identify combustible dust risks in facilities. The process involves testing dust combustibility, evaluating hazards, and implementing safeguards. While NFPA isn’t an enforcement agency, fire marshals, OSHA, and insurance carriers often require DHAs.

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SonicAire fans aren’t “OSHA certified” because OSHA is an enforcement agency, not a certification body. However, the fans comply with NFPA standards (which OSHA enforces) for combustible dust control, making them OSHA-compliant when properly implemented. This is why we offer our compliance guarantee, which also includes our endless warranty.

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Class II environments involve combustible dust hazards as defined by NFPA 499. Determining if your facility is Class II requires: 1) Testing if your dust is combustible, 2) Evaluating if hazards exist regularly (Division 1) or infrequently (Division 2), and 3) Consulting with an Authority Having Jurisdiction like a fire marshal. Class II ratings impact equipment requirements.

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Ignoring dust accumulation creates serious risks including combustion, fire, operational shutdowns, financial damage, and potential employee injuries or fatalities. SonicAire systems eliminate these risks by preventing dust from accumulating in overhead areas, removing the need for unsafe manual cleaning.

Fan Basics

What is SonicAire's process for implementing a dust control solution?

SonicAire’s four-step process includes: 1) Discovery – understanding your facility and dust challenges, 2) Design – creating a customized solution, 3) Delivery – implementing the system with installation options, and 4) Defend – providing ongoing support with a compliance guarantee.

Watch the full video

SonicAire fans offer precise airflow control through the iDrive system (adjustable up/down movement between 35-120 degrees) and optional Zone Control Kits that prevent the fan from blowing in sensitive areas during rotation.

Watch the full video

SonicAire fans should never be made mobile as this creates serious safety hazards: it defeats the proactive design purpose, may create combustible dust clouds, violates safety certifications, and breaks NFPA 660 guidelines requiring continuous operation during processes.

Watch the full video

SonicAire fans complement existing dust collection systems rather than replacing them. While filtration captures dust at the source, fans prevent the escape of “fugitive dust” from settling in overhead spaces, creating a complete dust management solution.

Watch the full video

Unlike conventional fans, SonicAire fans don’t simply blow dust around. Their BarrierAire technology disrupts thermal currents and uses agglomeration (making particles stick together and become heavier) to prevent dust from reaching overhead spaces, actually improving air quality.

We know it sounds crazy but we actually make the air quality better.

Watch the full video

SonicAire offers three levels of Preventative Maintenance Plans that include mechanical inspections, electrical testing, cleaning, and troubleshooting. Professional maintenance extends warranty coverage, prevents downtime, and ensures optimal performance.

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While Cubic Feet per Minute (CFM) is a standard specification for HVAC fans, SonicAire focuses on entrainment velocity (minimum velocity needed to move dust particles) and maximum velocity at distance. CFM alone doesn’t tell the complete performance story for dust control applications.

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We are always here to help you with your fan. If you do have issues reach out on our website through the support form. We respond within 1 business day.

The most common issues with SonicAire fans are: 1) Incorrect sway brace and safety cable installation (cables must be taut, braces at 90° angles), 2) Improper iDrive setup affecting vertical oscillation, 3) Fans blowing on sensitive processes due to incorrect adjustment, 4) Inadequate fan cleaning causing buildup, and 5) Inconsistent operation when fans are manually switched off.

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Beyond compliance, SonicAire fans provide multiple safety benefits: they reduce workplace hazards by eliminating the need for employees to work at heights, improve air quality through dust agglomeration, can help transform hazardous locations into unclassified areas, and reduce heating costs by recirculating warm air.

No, SonicAire fans complement rather than replace dust collection systems. Collection systems capture dust at the source, while SonicAire fans prevent “fugitive dust” (the dust that escapes collection) from accumulating in overhead spaces. Even the best collection systems aren’t 100% efficient due to filter blinding, incomplete capture at collection points, process changes affecting ductwork efficiency, and dust clinging to materials as they move through processes.

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Installation

What electrical infrastructure is needed to install SonicAire fans?

Our fans require 3-phase power (208-575 volts) and consideration of five key electrical factors: motor control center location, Area Classification (hazardous vs. non-hazardous), group fan controls, individual fan circuit protection, and Fan Zone Controls for sensitive areas.

We do offer turn-key installation, or we can work with your contractor to help install them.

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SonicAire offers multiple installation options: field support, preventative maintenance, parts and service, OEM parts, factory service, full turnkey installation by their team, mechanical installation with customer handling electrical, installation support/guidance for DIY customers, or just startup/commissioning services. All professional installation options add an extra year of warranty.

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Pre-cleaning is strongly recommended before first-time fan startup to prevent creating dangerous dust clouds. If pre-cleaning isn’t possible, there are alternatives but you will need to call us to talk through other options.

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The final two steps of SonicAire’s process include: 3) Deliver – receiving a proposal with system design, installation options, and pricing, followed by the manufacturing of your personalized fan systems in Winston-Salem, complete with 17-point inspection by hand; 4) Defend – system operation with compliance guarantee, ongoing support, and preventative maintenance options for an endless warranty.

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Pricing

How can I calculate the return on investment for a SonicAire dust control system?

SonicAire offers a free ROI calculator to determine the payback period for dust control fan systems. The calculation takes into account your dust type, facility size, current cleaning costs, production downtime, and electrical costs. Beyond financial returns, benefits include safety compliance and a healthier workplace through cleaner air and more comfortable temperatures.

Watch the full video

A single SonicAire fan typically covers 4,000-6,000 square feet, depending on dust type, facility conditions, and fan model. Every SonicAire Fan System comes with a complimentary engineered layout tailored to your facility’s specifications, dust type, and processing environment, ensuring compliance.

Watch the full video

SonicAire fan systems typically cost around $2.50 per square foot installed; however, factors such as dust type, area classification, temperature/moisture conditions, installation accessibility, and electrical infrastructure can affect the final pricing.

A fan system only needs to be installed in areas where your process produces fugitive dust.

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Yes! We offer a 60-day Try & Buy program, allowing you to test a fan with no obligation. The program requires a purchase order upfront, but if customers are unsatisfied, they can return the fan for a full refund. However, we find that most customers keep them after seeing the results

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Our fans cost more than standard industrial fans because they’re engineered systems with proprietary BarrierAire technology, automated oscillation, high-velocity airflow, and industrial-grade components. They’re American-made, NFPA-compliant, and backed by a safety compliance guarantee that standard fans won’t offer.

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The first two steps of SonicAire’s process include: 1) Discover – initial consultation to understand your dust challenges, facility constraints, and budget needs, determining if SonicAire is right for you; 2) Design – gathering detailed facility information (drawings, photos, obstructions) to create a customized engineering solution with the right fan placement.

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Our fans deliver exceptional return on investment through automated dust control that eliminates expensive manual cleaning (which can cost $200,000+ annually), prevents regulatory fines, reduces downtime, extends equipment life, increases employee satisfaction, and comes with the industry’s only safety compliance guarantee.

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An engineered layout is essential because proper fan placement depends on multiple factors: dust type/behavior, facility structure, obstructions, sensitive processes, and electrical constraints. Random placement risks inadequate coverage, energy waste, and non-compliance. SonicAire’s engineering team designs systems with the optimal number and placement of fans to ensure complete coverage with the fewest units possible, maximizing ROI and compliance guarantee effectiveness.

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How SonicAire Can Help

SonicAire utilizes precision dust-control technology, engineered specifically for the plastics industry. SonicAire’s industrial control fans proactively prevent combustible dust build-up, thereby maintaining a clean and safe environment in a cost-effective manner.

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Additional Resources

Learn more about how we helped companies like yours find solutions to their dust problems.

Linen Industry Case History
Plastics Industry Case History

Complimentary Dust Management Plan with ROI Analysis

SonicAire is committed to helping our clients tackle combustible dust in their facilities. We will review your facility specifications and develop a custom analysis of how SonicAire fans can use our BarrierAire™ technology to reduce combustible dust accumulation, improve worker safety and productivity and keep your facility compliant with OSHA and NFPA regulations.

Our analysis will also show you the expected Return on Investment, including equipment investment, estimated annual savings and cumulative cashflow benefit.

Get started by contacting us today for your custom facility review, ROI analysis and fan technology proposal.

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