Filter Maintenance: The Most Common (and Costly) Mistake in Dust Control

A frequent mistake on job sites is delaying filter changes to “save money.” In reality, the opposite happens: performance drops, airflow collapses, exposure limits are exceeded, and the machine begins to feel like it “doesn’t work anymore.” What follows is often expensive repairs and preventable downtime.

Filters are not optional extras; they are the heart of dust control. Under COSHH, employers must keep control measures in an efficient state, in efficient working order, and in good repair. If filters are clogged, damaged or bypassed, LEV systems, air scrubbers and industrial vacuums cannot control respirable crystalline silica (RCS) to the UK Workplace Exposure Limit (WEL) of 0.1 mg/m³.

What Needs Checking

Focus your checks on the devices actually doing the work: tool-mounted extraction, LEV hoods and ducting, negative air machines, air scrubbers and H/M-Class vacuums with HEPA final stages.

• Inspect filter media for tears, pinholes or contamination.
• Check seals and gaskets for wear, compression loss or visible leaks.
• Ensure bags and bins are not overfilled.
• Verify housings close correctly with no gaps or warped frames.
• Measure airflow under load — not free-air values — because filter loading changes performance dramatically.

Where fitted, read differential pressure gauges and trend the numbers over time. Rising pressure at steady duty indicates loading or blockage. For RCS and ultrafine dusts, HEPA H13 or ideally H14 final stages should be used — and they only protect if upstream filters and seals are sound.

A Simple Site Routine

Daily

• Visual inspection for damage and leaks.
• Confirm pressure gauges are within expected range.
• Empty bins and bags safely.
• Ensure auto-clean (if fitted) is actually operating.

Weekly

• Conduct an airflow test with the tool connected.
• Inspect all seals, hoses and latches.

Monthly

• Open the unit and inspect internal filter stages.
• Replace filters that are damaged or as recommended by the manufacturer.
• After high-dust tasks or any wet work, re-check immediately.

Air scrubbers and H-Class vacuums from suppliers such as MAXVAC rely on correct filter seating and intact seals. Quick, routine checks prevent uncontrolled exposures and significantly reduce downtime.

Recording and Evidence

Keep simple, consistent records of your checks — date, plant ID, location, gauge readings, airflow results, defects found, and corrective actions taken. Under COSHH Regulation 9, LEV systems require thorough examination and testing at regular intervals. Your on-site routine supports that duty and helps examiners diagnose issues early.

Key Takeaways

• Check filters, seals and bins daily.
• Verify airflow under load weekly.
• Trend differential pressure readings and investigate sudden changes.
• Use H14 final filters for fine or carcinogenic dusts such as RCS.
• Record all findings and schedule LEV examinations on time.

Regular filter checks are a simple habit that turn compliance into consistent control — protecting workers, machinery and productivity.