EPA-DEFENSIBLE
REAL-TIME AIR DATA.
Continuous baghouse health monitoring. Differential pressure, opacity, stack temperature, particulate matter (PM2.5/PM10), CO₂, VOC, H₂S. Catches bag failures before EPA violations. Audit-ready timestamped records replace clipboard rounds.
VISIBLE EMISSIONS = FINES + SHUTDOWNS.
Cement plants, battery manufacturers, and heavy-industry sites face increasingly stringent emissions regulations. A single baghouse bag failure can trigger an EPA violation, costly fines, and forced shutdown. Manual inspections happen weekly at best — by then, the violation is already on record. DustIQ catches the failure in minutes, not weeks.
FROM CLIPBOARD TO CONTINUOUS.
Sensor Each Baghouse
Differential pressure across the baghouse. Opacity stack monitor. Temperature, fan status, particulate matter. Wireless install. No conduit, no IT involvement. Class I Div 2 hazardous-area variants for explosive dust environments.
Real-Time Dashboards
Live baghouse status grid: BH-01 Normal, BH-02 Warning, BH-03 Critical. Differential pressure trend, opacity excursion alerts, fan status. Manage by exception — supervisors only react to deviations.
Defend Compliance
Every reading timestamped and stored. EPA-defensible audit trail with chain-of-custody. Auto-generated emissions reports. When the auditor asks, you don't dig through clipboards — you click "export."
Predict Bag Failures
AI baseline on dP trends. When a bag tears, dP shifts before opacity spikes. Maintenance team gets alerted hours before the EPA-visible event. Schedule repair during planned downtime, not at 2am.
EPA-DEFENSIBLE AIR QUALITY.
EVERY DUST SOURCE. EVERY SHIFT.
Baghouse Differential Pressure
Continuous dP monitoring across each baghouse compartment. Catches bag failures, broken pulse-clean valves, blinded filters. Class I Div 2 rated for combustible dust environments.
Particulate Matter (PM2.5 / PM10)
Real-time PM measurement at stack and ambient. ASHRAE 62.1 and EPA-grade reference variants. Outdoor station with weather (NO₂, O₃, SO₂, wind, rain) for full site air quality.
Indoor Air Quality
CO₂, VOC, PM, T°, RH for offices, control rooms, plant floors. ASHRAE 62.1 thresholds. Live at JAX International terminals and Campus360 K-12 deployments.
Stack Opacity & Temperature
Continuous stack opacity (EPA Method 9 equivalent). Stack temperature for thermal compliance. Tied to baghouse alerts — opacity spike triggers immediate ops notification.
EPA-Defensible Records
Every reading timestamped, location-tagged, and stored immutably. Auto-generated compliance reports. 40 CFR Part 60 / 63 audit-ready. Chain-of-custody from sensor to report.
Live at Clarios + IAC Cement Plants
14 sensors in Clarios Toledo oxide rooms. 100+ baghouse systems across IAC engineering deployments in cement, mining, and battery manufacturing.
IN PRODUCTION
Baghouse + rotating equipment monitoring in oxide rooms. EPA-defensible audit trail. Manufacturing reliability + air quality compliance on one platform.
Continuous monitoring across cement plant baghouses. Reduced downtime by 10–20%. OEE improvements of 5–15%. $300K/day-of-downtime risk mitigated at each 1 MTPA plant.
Suspension preheater, raw mill, electrostatic precipitator, rotary kiln, packing house — every dust source monitored. Replaces manual rounds. Avoids visible emission events.
COMMON QUESTIONS
WILL IT INTEGRATE WITH OUR EXISTING CEMS?+
Yes. DustIQ complements continuous emissions monitoring systems (CEMS) — it doesn't replace them. We provide higher-frequency dP and PM data feeding into your existing 40 CFR compliance program. Modbus, OPC UA, or REST integrations.
ATEX / CLASS I DIV 2 VARIANTS?+
Yes. The baghouse dP monitor is Class I Div 2 rated for combustible dust environments. ATEX Zone 21/22 variants available for European cement plants and grain handling.
HOW DOES THE EPA AUDIT TRAIL WORK?+
Every sensor reading is timestamped, sensor-ID-tagged, and stored immutably in IoTLogIQ. Exports as auditor-ready PDF or CSV. Chain-of-custody preserved from sensor through cloud. Compliant with 40 CFR Part 60, Part 63, and state-equivalent regs.
WHAT'S THE ROI?+
Customer data: 10–20% maintenance cost savings, 5–15% OEE improvement (McKinsey cement industry benchmark). At a 1 MTPA cement plant, one avoided unplanned downtime day = $300K. DustIQ pays back on the first prevented bag failure.
CAN WE DEPLOY ON ONE BAGHOUSE FIRST?+
Yes — that's the standard pilot. One baghouse, one operations owner, 90 days. Pilot scales to plant-wide deployment, then to multi-plant network on the same platform.
PILOT IN 30 DAYS.
One area. One owner. One problem. Live data on the call, not slides.