From Clogged Filters to Clean Air: A Six-Year Maintenance Overhaul

From Clogged Filters to Clean Air: A Six-Year Maintenance Overhaul

The Challenge

After six years of continuous 24/5 operation, a client's air filtration systems had never undergone a complete filter maintenance.

The metal mesh filters were heavily saturated with particulate matter and solids, leading to compromised system performance.

This was evident in elevated fan speeds (up to 93%) and differential pressure readings over -0.10. In the Compounding area, excessive oil in the air and on nearby surfaces raised additional concerns from the maintenance team.

The Solution

Kogi Environmental Solutions conducted an on-site inspection and identified the primary cause of the performance issues: clogged mesh filters that had not been cleaned or replaced since installation.

We recommended:

• Soaking metal mesh filters in Simple Green solution and power-washing them to

restore airflow.

• Ordering a second set of filters for seamless changeovers without halting operations.

• Replacing aged tubing on the differential pressure sensor and cleaning the housing.

• Blowing out barbed fittings with compressed air to clear blockages.

• Semi-annual preventive maintenance on sensors and fittings moving forward.

We also noted a fault in the HMI caused by oil contamination in the pressure sensor line

and poor tubing fit, and provided guidance on restoring sensor accuracy.

Discover how we turned years of neglect into clean, efficient air.
Download the full case study brochure  and see the results for yourself.