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How can PowerCore be so much smaller than a traditional baghouse?

There are two reasons PowerCore is smaller: the filter packs and the collector design.

One PowerCore filter pack replaces six traditional fabric filter bags. We are able to include a large amount of filter media area in the 178-mm filter pack space because of the unique corrugated configuration method. With shorter filter packs, the size of the collector can be reduced.

The collector is designed to be smaller and smarter. By engineering the airflow patterns inside the collector, we have been successful in reducing the amount of space required while maintaining excellent filtration performance.

Does PowerCore improve traditional baghouse filtration?

Yes. The PowerCore collector design and engineered airflow work to prevent a common baghouse problem – bridging. The possibility of dust bridging between the filters is eliminated in PowerCore.

By designing the filter pack and the collector together, Donaldson has developed an optimized solution for dust collection where baghouses are typically applied.

Can dust bridging become a problem with PowerCore?

No. There is no chance of bridging between PowerCore filter packs -- and therefore no plugging due to bridging – in a PowerCore collector. Here’s why:

  • Bridging happens in baghouses because the pulse-cleaning knocks accumulated dust down the length of the filter, and often it accumulates in the lower interstitial spaces. On particulate that tends to stick to itself or nest, the accumulation builds, eventually into a bridge. PowerCore is engineered with computer-modeled fluid flow analysis to manage the incoming dirty air and the velocities directed into the filter pack, avoiding interstitial problems. And, the PowerCore filter pack is only 178 mm deep, so there’s virtually no opportunity for a dust bridge to develop.
  • Donaldson’s new Compact Oblique Pulse Cleaning System is a patented, computer-modeled pulse-cleaning technology designed to match the obround shape of the PowerCore filter pack. The pulse pattern covers the entire media pack and pulses the dust out of the fluted channels. There is no possibility of bridging.

What kind of dust can PowerCore handle?

So far, we’ve tested and approved PowerCore for many industries where baghouses are typically applied, including:

  • Cement & Gypsum
  • Food Products
  • Mining & Quarry
  • Grain – Milling & Processing
  • Paper & Packaging
  • Plastics
  • Glass
  • Textiles
  • Rubber
  • Wood – Lumber, Furniture & Millwork (including very fine wood flour)
  • Rockwool

We continue to test and develop PowerCore solutions for other dust challenges. Donaldson will always recommend the best filtration solution for the specific application, whether it’s a cartridge, baghouse, or PowerCore.

Is the PowerCore filter a bag or a cartridge?

The PowerCore filter is neither a bag nor a cartridge. It’s a filter pack with a handle. We’ve configured the media into a corrugated flute structure, which not only makes the pack rigid and sturdy, but allows more media to be used effectively in a smaller volume. The media is then rolled into an “ob-round” shape that is only 178 mm deep by 569 mm long. The PowerCore filter pack, in conjunction with the PowerCore collector, has been designed to replace conventional baghouses with fabric or pleated filter bags.

You’ll be amazed at how easy it is to change out the PowerCore filter packs. They can removed and replaced in just minutes, without using tools – and without a confined space permit.

What kind of filter media is used in PowerCore filter packs?

Our best: our Donaldson-developed and patented Ultra-Web® media. It’s made of two layers -- a sturdy substrate bonded with a thin layer of nanofibers – that capture both small and large particulate – resulting in a very high performance media.

The EPA PM2.5 testing proves it. PowerCore filter packs have 78% FEWER emissions than traditional polyester filter bags.

Can I retrofit my current collector with PowerCore filter packs?

Not at this time. PowerCore uses an advanced filtration technology. The filter packs, tubesheet, oblique pulse-cleaning system and engineered airflow of the collector have been optimized as an integrated system. Retrofitting an existing collector is not advised.

How do I know what size collector I need?

There are many parameters that influence a recommendation on collector size including dust characteristics, airflow rate, and duty cycles. Donaldson has extensive expertise in matching the right collector to the application to make sure the collector is sized appropriately for optimal performance. Please call us directly to get an answer for your specific application: +32 16 383 970.

Are PowerCore and PowerCore filter packs available from other manufacturers?

No. PowerCore and PowerCore filter packs are only available from Donaldson. An extension of Donaldson Company’s PowerCore technology—which is backed by 100 pending & issued patents and is well-proven in engine filtration—PowerCore dust collectors and PowerCore filter packs are the first major baghouse innovation in decades.