SINCE 1990
Industrial Dust
4-Stage Integrated Fan Solution
Main · Mid · Vent · ATEX explosion-proof — RDH + LWBE3G + ADH + AT-ATEX one-stop coverage. BESS · Semiconductor · Grain · Metal Machining · Pharma · Chemical. One supplier, four stages, zero finger-pointing.
Why LONGWELL uniquely covers the full industrial dust chain
Most fan vendors target a single niche — HVAC, industrial blowers, or ventilation fans separately. LONGWELL is the rare supplier that engineers all three categories in-house, with a unified Modbus / ATEX / 8D framework. This is what makes the integrated dust collection solution coherent.
Full 4-stage product breadth
RDH industrial heavy-duty + LWBE3G backward-curved + ADH large-airflow + AT-ATEX explosion-proof — covering the full 300-2,500 Pa pressure range. All satisfy 24/7 industrial duty cycle and 60,000h MTBF commitment.
Unified Modbus + 8D single-point contact
All 4-stage EC platforms share the same Modbus register map — central PLC integration developed once covers the entire system. Single contact window for any plant-wide issue; 8D closed loop with zero finger-pointing.
Full ATEX zone coverage
REM EC ATEX + RDH ATEX + AT ATEX + ADH ATEX — four series cover all ATEX zones for lithium / grain / chemical / paint booth applications (Zone 21/22 + Zone 2).
90-day NPI vs European 12 months
vs European competitors' 12-month NPI, LONGWELL's 90-day custom cycle has delivered 350 REM ATEX EC units to a North American BESS customer (first batch of 80 units in 3.5 weeks).
Field engineers in three regions
European / North America / Middle East / Asia offices deploy local engineers on demand. BESS / semiconductor / pharma and other critical industries receive 2-6 weeks of on-site field service by default.
To Our Industrial Dust Partners
To industrial dust engineering, procurement, and safety leaders:
In most factories, dust fans are the "invisible energy champion" — but the cost of failure dwarfs HVAC fan failures. Production line downtime runs USD 8,000-50,000 per hour, OSHA/NFPA fines hit USD 14,500-145,000 per violation, and worker health claims plus insurance premiums rise 20-40%. Dust collection consumes 18-30% of a large facility's total electricity — second only to process equipment itself.
Industrial dust systems are not a single fan — they are a multi-stage air handling system. The main blower at 1,800-2,200 Pa pulls dusty air through the filter bank; mid-stage transfer fans move clean air at 600-1,200 Pa; large-volume ventilation runs ≤ 800 Pa; ATEX explosion-proof variants serve flammable-dust environments. Sourcing each stage from a different vendor creates SKU sprawl, mismatched controls, and zero single-point accountability. LONGWELL solves it with an integrated portfolio.
This Pack documents our solution and engagement model. §2 details the 4-stage product solution; §3 covers six industries — BESS / semiconductor / grain / metal / pharma / chemical; §4 presents three anonymized customer cases; §5 and §6 cover engineering support and engagement paths.
The Real Cost of Dust System Failure
In most factories, dust fans are the "invisible energy champion" — but the cost of failure dwarfs HVAC fan failures. The four items below make up the true total cost of dust system failure (annualized for a typical large facility).
Production Line Downtime
USD 8,000-50,000 / hour
Main blower failure → dust system paralysis → entire line forced stop. Semiconductor / lithium / pharma typical downtime cost: $25-50K/h.
Compliance Fines
USD 14,500-145,000 / violation
NFPA 855 / NFPA 33 / OSHA 1910.1000 non-compliance; BESS factory ATEX failure can trigger full facility shutdown.
Worker Health + Insurance
Premiums up 20-40%
Dust exposure exceeds limits → long-term health damage → workers' compensation claims + insurance premium increases.
Wasted Electricity
18-30% of total electricity
Dust collection is the #2 energy center in most factories (second only to process equipment). AC + legacy VFD consumes 40% more than EC.
Industrial dust systems are not a single fan — they are a multi-stage air handling system. Sourcing each stage from a different vendor creates SKU sprawl, mismatched controls, and zero single-point accountability. LONGWELL solves it with an integrated portfolio: RDH main + LWBE3G mid + ADH large-volume + ATEX cross-series variants.
Industrial Dust 4-Stage Architecture & Product Mapping
Below is the canonical 4-stage architecture of an industrial dust collection system. Each stage has different pressure / airflow / environmental requirements and demands a purpose-engineered fan. The LONGWELL Industrial Dust Solution maps one product family to each stage.
Main Blower
Main Blower
Pulls dusty air through the filter bank — RDH industrial heavy-duty centrifugal.
Mid-Stage Transfer
Mid-Stage Transfer
Clean-air booster between filter stages — LWBE3G backward-curved EC.
Large-Volume Vent
Large-Volume Vent
Facility-wide background dilution — ADH belt-driven heavy-duty forward-curved.
ATEX Explosion-Proof
Hazardous-Zone Variant
Cross-series variants for flammable dust — AT-ATEX + ATEX versions of stages 1-3.
| Stage | Role | Pressure | LONGWELL Series | Typical Use |
|---|---|---|---|---|
| ① | Main Blower — pulls dusty air through filter bank | 1,500-2,500 Pa | RDH | Dust collection main / flue gas / BESS exhaust |
| ② | Mid-Stage Transfer — clean air booster between stages | 600-1,500 Pa | LWBE3G | Post-filter booster / secondary transfer |
| ③ | Large-Volume Ventilation — facility air dilution | 300-1,000 Pa | ADH | Workshop dilution / factory supply air |
| ④ | ATEX Hazardous-Zone Variant | Full range | AT-ATEX + above | Lithium / grain / chemical / paint booth |
Product Selection · 4-Stage Precise Configuration
Each stage's fan configuration matches the process pressure / airflow / environment and the certification matrix.
① RDH Main Blower Typical Sizing
The main blower sits downstream of the filter bank and creates the negative pressure that pulls the whole system. RDH 11 backward-inclined steel blades, G1.0 industrial-grade balance, wear-resistant coating for dusty conditions. Five mainstream sizes 400-630 mm carry ATEX Zone 22 as standard.
| Dust Scale | Airflow m³/h | Pressure Pa | Recommended | Motor kW |
|---|---|---|---|---|
| Mid-size (single station) | 4,500-12,000 | 1,500-1,800 | RDH-355 / 400 | 5.5-15 kW |
| Large (multi-station / full workshop) | 13,500-25,000 | 1,800-2,200 | RDH-500 / 560 | 18.5-30 kW |
| Extra-large (full-facility central) | 25,000-50,000 | 2,000-2,500 | RDH-630 / 710 / 900 | 30-55 kW |
▸ RDH Field Reliability Data (10-month average)
| Metric | Target | Field-Measured |
|---|---|---|
| MTBF (@ 40°C) | 60,000 h | 68,200 h (13% above target) |
| Year-1 field failure rate | < 0.5% | 0.18% (BESS deployment) |
| 8D closed-loop time | < 15 business days | 11.2 business days avg |
| Field service response | ≤ 48 hours on-site | 36 hours avg (North America) |
② LWBE3G Mid-Stage Typical Sizing
The mid-stage transfer fan sits between filter stages in a multi-stage system. Third-generation backward-curved platform, EC direct-drive integration, Modbus RTU standard, EMC Class B certified (semiconductor / pharma cleanroom), ≤ 68 dB(A) at 1 m.
| Transfer Stage | Airflow m³/h | Pressure Pa | Recommended | Motor kW |
|---|---|---|---|---|
| Primary → secondary filter | 4,000-8,000 | 800-1,200 | LWBE3G-400 / 450 | 3.0-7.5 kW |
| Secondary → HEPA / post-treatment | 8,000-15,000 | 1,000-1,500 | LWBE3G-500 / 560 | 7.5-15 kW |
| Distributed system mid-boost | 3,000-12,000 | 600-1,000 | LWBE3G-355 / 400 | 2.2-5.5 kW |
③ ADH Large-Volume Ventilation Typical Sizing
Stage 3 handles what filters can't — the facility-wide background. Even with high-efficiency point-source capture, large industrial spaces need volumetric dilution. ADH is the workhorse: belt-driven heavy-duty forward-curved, up to 60,000 m³/h per unit at moderate pressure (≤ 1,000 Pa).
| Use Case | Airflow m³/h | Pressure Pa | Recommended | Motor kW |
|---|---|---|---|---|
| Mid-size workshop (< 5,000 m²) | 8,000-20,000 | 400-700 Pa | ADH-630 / 710 | 5.5-15 kW |
| Large workshop (5,000-20,000 m²) | 20,000-40,000 | 500-800 Pa | ADH-900 / 1000 | 18.5-37 kW |
| Extra-large (> 20,000 m²) | 40,000-60,000 | ≤ 1,000 Pa | ADH-1120 / 1250 | 37-55 kW |
④ ATEX Explosion-Proof — Cross-Series Engineered
ATEX is not a sticker — it is six specific engineering changes. LONGWELL ATEX spans the first three stages across the full range: RDH ATEX (main), REM ATEX (compact high-pressure), AT ATEX (forward-curved belt), and ADH ATEX (large-volume).
| Hazard Environment | ATEX Marking | LONGWELL Series | Examples |
|---|---|---|---|
| Lithium battery factory (occasional dust) | II 3D Ex tc Zone 22 | REM ATEX EC | BESS emergency exhaust |
| Pharma powder (frequent dust) | II 2D Ex tb Zone 21 | RDH ATEX-21 | Tablet workshop dust |
| Chemical workshop (occasional gas) | II 3G Ex nA IIA T3 | AT ATEX-G | Solvent workshop ventilation |
| Paint booth | II 3G Zone 2 + NFPA 33 | ADH ATEX-G | Auto / furniture paint |
| Grain / wood / cement | II 3D Zone 22 | RDH ATEX + ADH ATEX | Flour mill / wood processing |
| Mixed environment (dust + gas) | II 3GD combined | REM / RDH ATEX-GD | Lithium cell coating workshop |
Nicotra ATEX typical lead time: 10-12 weeks (EU production + sea freight). LONGWELL ATEX typical lead time: 4-5 weeks (China production + sea freight + air-freight option). On-site Notified Body (SGS / TÜV) inspection at the Ningbo factory means a short certification cycle; urgent projects can be prioritized in production scheduling.
Six Industries · One Product Portfolio
BESS · Semiconductor · Grain · Metal Machining · Pharma · Chemical — six industries that look very different, but all share the same LONGWELL 4-stage product inventory. One commercial team + engineering team + spare parts inventory + 8D process — saves 40-60% on whole-plant integration time vs multi-vendor sourcing.
The table below shows the typical LONGWELL configuration reference for each industry. Full specs, application notes, and compliance regulations are in §3 (p13-18).
| Industry | Core Configuration | Key Compliance |
|---|---|---|
| BESS Lithium | REM ATEX EC + RDH ATEX-21 | NFPA 855 · UL 9540A |
| Semiconductor | LWBE3G EC + RDH FRP + AT | EMC Class B · < 1.8 mm/s |
| Grain | RDH ATEX-22 + ADH ATEX | NFPA 61 · EN 14491 |
| Metal | RDH + LWBE3G + ADH | OSHA PEL · IE4 |
| Pharma | RDH ATEX-21 + 316L stainless | FDA 21 CFR · EU GMP |
| Chemical / Paint | AT ATEX-G + RDH FRP | NFPA 33 · EN 13478 |
Cross-Series Shared Certification Matrix
All certificates are held by LONGWELL; original PDFs are available on request. Gold-highlighted certifications carry the heaviest weight in dust customer audits.
| Certification | Standard | Coverage |
|---|---|---|
| CE | EU Marking · Machinery / EMC / LVD | All 4-stage series |
| ATEX + IECEx ★ | ATEX 2014/34/EU + IECEx Scheme · Zone 21/22 + Zone 2 | REM EC · RDH · AT · ADH |
| UL | UL 507 (fan) + UL 1004-1 (motor) | All NA mainstream sizes |
| EMC Class A/B ★ | EN 55014-1 / EN 55014-2 | Full EC platform (Class B for semi scenarios) |
| ErP Tier 2 ★ | EU Energy-related Products · 2027 mandatory | EC platform and IE4 motors |
| NFPA / EN 14491 ★ | NFPA 33 / NFPA 61 / NFPA 855 / EN 14491 | ATEX series meets all US/EU mainstream dust codes |
| EN 12952 | Water-tube Boiler Standard (flue gas) | RDH high-temp version |
| RoHS / REACH | EU 2011/65/EU + (EC) 1907/2006 | All 4-stage series |
| ISO 9001 / 14001 / 45001 | Quality + Environment + Safety Management | ✓ Certified |
| BSCI + SEDEX | Social Compliance Audit | ✓ Audited |
Test Report Library
T1 = PDF available within 1 business day; T2 = scheduled at named lab. T1-T3 services are complimentary for project-intent customers.
| Test Type | Standard | Coverage | Status |
|---|---|---|---|
| Aerodynamic P-Q Curves | AMCA 210-16 / ISO 5801 | All 4 stages | ✓ T1 Ready |
| Acoustic Lw / Lp | ISO 3744 / ISO 13347 | All 4 stages | ✓ T1 Ready |
| Vibration G1.0 / G2.5 | ISO 14694 / ISO 1940 | All 4 stages | ✓ T1 Ready |
| ATEX Type Test | EN 60079 Zone 21/22/2 | ATEX 4 series | ✓ T1 Ready |
| Dust-laden wear test | ASTM G65 / LONGWELL internal | RDH series | ✓ T1 Ready |
| High-temperature flue gas | EN 60068-2-2 / 200°C 168h | RDH high-temp version | ✓ T1 Ready |
| Salt spray corrosion | ISO 9227 / 480h | FRP / stainless versions | ✓ T1 Ready |
| L10 accelerated aging (batch) | ISO 281 (60,000h) | All 4 stages sampled | ✓ T1 Ready |
| EMC IT environment (semi) | EN 55014 Class B + FCC | LWBE3G / REM EC | ✓ T1 Ready |
| GMP DQ/IQ/OQ/PQ | FDA 21 CFR Part 11 + EU GMP | Pharma versions | ✓ T1 Ready |
Case 1: Top-5 North American BESS Manufacturer
Customer name disclosable under separate NDA. Large lithium battery factories in Texas and Nevada, 2025 capacity target 20 GWh. Data verified by LONGWELL PMO and confirmed by customer's procurement and safety team.
Project Context & Hard Requirements · 2024 Q3
- Facility safety audit trigger — Q3 2024 safety audit identified that the cell coating and formation workshops lacked sufficient emergency exhaust to comply with NFPA 855 + OSHA lithium battery safety requirements.
- 6-month timeline to complete ATEX retrofit — approximately 350 high-pressure blowers; full II 3D Cat. 3 ATEX compliance, 3-second emergency start, Modbus + dry contact interlocked with Siemens FailSafe.
- First 80 units delivered within 4 weeks — UL North American certification; European suppliers' 12-month NPI could not meet the deadline.
LONGWELL Solution & Project Outcomes
| Metric | Customer Required | Achieved |
|---|---|---|
| ATEX certification coverage | II 3D Cat. 3 | All 350 units passed |
| Emergency start response | ≤ 3 seconds | 1.8 seconds (measured) |
| 0 → rated speed | ≤ 10 seconds | 7.5 seconds (measured) |
| First 80 units delivery | 4 weeks | 3.5 weeks (ahead of schedule) |
| Field quality incidents (10 months) | ≤ 1% | Zero major incidents |
| 2025 full-year orders | — | Additional 350 units (REM 500/560) |
| Frame agreement | — | 2025-2027 three-year priority supply |
Case 2 + Case 3 Summary
| Dimension | Case 2 · European Grain | Case 3 · Asian Semiconductor |
|---|---|---|
| Scale | 168 units across 14 EU facilities | 280 units single-fab integration |
| Key Challenge | Nicotra retrofit compatibility + 6-month deadline | Unified Modbus integration + 12-week delivery |
| LONGWELL Key Capability | Nicotra 1:1 compatibility + ATEX velocity | 4-series unified Modbus + G1.0 balance |
| Lead Time | 5.2 months (vs Nicotra 10 months) | 10 weeks for 280 units (vs 12-week target) |
| Cost Savings | vs Nicotra 38% lower | vs multi-vendor 28% lower |
| Commercial Outcome | 5-year frame agreement | Phase-2 fab order 320 units |
Common pattern: None of the three cases were won on price alone — what customers really paid for was delivery certainty + ATEX compliance velocity + single-supplier integration. LONGWELL's edge is not cheapest pricing — it is the speed-plus-completeness combination that European suppliers cannot match in reasonable time windows.
Dust-Specific Engineering Support
LONGWELL provides industry-specific engineering tools for dust collection projects — beyond the standard Commercial Blower Portfolio toolkit. The dust-specific tools below address full-system design, ATEX zoning, and integration with leading filter / dust collector manufacturers.
| Tool | Purpose | Access |
|---|---|---|
| Full-facility Dust CFD Simulation | Whole-facility dust system CFD simulation predicting main blower match point, mid-stage transfer match, full-facility airflow distribution, and explosion pressure relief path | Free for project intent |
| ATEX Zone Classification Map | Generates customer facility ATEX Zone classification map per EN 60079-10; recommends ATEX marking + installation location per fan | ATEX projects exclusive |
| LONGWELLBUS Selection Software | Input operating point (airflow / pressure / medium / application); returns full 4-stage configuration + complete P-Q-η curves | Free download |
| Dust Collector Integration Manual | LONGWELL fan interface guide for Donaldson / Camfil / Nordfab leading dust collector brands | Free |
| Modbus Unified Register Map | All 4-stage EC platform fans share same register map; Siemens FailSafe / Rockwell GuardLogix integration manual | Available after NDA |
| 10-Year TCO Calculator | Whole-facility dust collection TCO: compare customer existing solution (Nicotra / Greenheck / other) vs LONGWELL 4-stage solution, 10-year TCO + payback period | Free |
| 3D CAD Library | All 4-stage sizes — STEP / IGES / Parasolid files; includes ATEX variant interface dimensions | Available after NDA |
Field Application Engineering
For strategic dust collection projects, LONGWELL provides on-site Field Application Engineering: 2-6 week deployment for integrated system commissioning, ATEX compliance acceptance, and mass production transition. Local engineers from EU / NA / Middle East / Asia offices. BESS / semiconductor / pharma projects include field engineering by default.
90-Day NPI + Reliability Framework
Custom dust collection projects follow LONGWELL's standardized 90-day NPI cycle — the same proven process that delivered the three customer cases in §4. Below is the process + commercial terms + warranty framework.
| Stage | Engineering Actions | Customer Involvement |
|---|---|---|
| S1 · Day 1-14 Spec Lock | Full-facility dust diagram + 4-stage parameters + ATEX level | Provide facility layout / process diagrams / dust properties / ATEX level / existing equipment list · 2-3 conference calls |
| S2 · Day 15-45 Design | Facility CFD + 4-stage configuration + ATEX compliance design | LONGWELL leads; customer receives full-facility CFD simulation / 3D model / ATEX documentation / performance predictions · one technical review |
| S3 · Day 46-70 Prototype | Engineering samples + customer factory integration + DV | LONGWELL leads; customer receives 1-3 samples per stage + performance/vibration/noise measurements + ATEX type test |
| S4 · Day 71-90 Release | DV/PV + mass production + first order | LONGWELL supports customer DV/PV + ATEX Notified Body third-party acceptance; mass production process archived, first order delivered |
Reliability Framework
100% in-line performance test
Every fan 100% tested for airflow / pressure / vibration / noise / temperature rise; data linked to serial number in MES for 10 years.
G1.0 / G2.5 dynamic balance
Industrial series (RDH / REM) G1.0 high-precision; HVAC series (LWBE3G / AT / ADH) G2.5.
24-hour Burn-in
Full-load continuous 24 hours to screen out early failures; EC drive boards 100% high-temp/high-voltage stress tested.
ATEX individual certificate per unit
ATEX versions individually certified with serial number; 1% spot-checked by Notified Body.
L10 accelerated aging
5 units per batch undergo 1,500-hour + 60°C accelerated aging, extrapolating L10 = 60,000h @ 40°C.
8D closed-loop support
24h acknowledgment → 5 business day root cause → 15 business day corrective action; emergency: engineer on-site within 48h.
Three Engagement Paths
Three engagement paths for industrial dust collection projects. Pick the one that fits your current project stage.
Quick Quote / Nicotra Replacement
Send operating spec list (any of the 4 stages or all) → receive matching LONGWELL series + models + performance curves + quote within 48 hours. Nicotra / Greenheck / other-brand 1:1 replacement mapping available.
Full-Facility Engineering Review
Sign NDA → provide facility layout + process inventory → LONGWELL full-facility CFD simulation + 4-stage solution recommendation + ATEX zone classification → customer factory technical review + on-site audit.
90-Day NPI Kickoff
Sign NDA → detailed requirement review → 90-day custom NPI kickoff → on-site Field Application Engineering deployment (default for strategic customers).
Get in Touch
Engineered for Where Air Carries the Cost.
One supplier across 4 dust stages — BESS · Semiconductor · Grain · Pharma · Chemical · Metal Machining. Where air carries the cost — engineer it once, supply it from one source.