A leading Australian recycling and resource recovery company continues to invest in innovative technologies and processes that support improved material recovery, safer operations, and enhanced environmental performance. As part of this commitment, Airtight Solutions has designed a custom Dry Fog Dust Suppression System to provide targeted dust control across critical areas of the company’s material handling process. The purpose-built system suppresses airborne dust at key transfer points, including the infeed hopper, hopper discharge into the fines bin, and other material receiving areas.

A Dust Suppression Solution Designed Around the Process 

Dust generation is a common challenge across recycling, resource recovery and bulk material handling operations, particularly at transfer points, hoppers and discharge locations where material movement can create airborne particles. For large-scale processing facilities, an effective industrial dust suppression system must integrate with the existing material handling process rather than simply treating the symptoms. 

Airtight’s Dry Fog technology delivers targeted dust suppression directly at the source. The system fills the treatment zone with ultra-fine fog droplets that attach to airborne dust particles, increasing their mass and allowing them to settle back into the product stream. This approach provides effective airborne dust suppression while using minimal water. The system controls dust while adding less than 0.05% moisture to the product stream, helping preserve product quality.

Supporting Innovation in Recycling and Resource Recovery 

Australia’s leading recycling and resource recovery operators manage complex material processing environments where dust control plays an important role in operational efficiency, workplace safety and environmental performance. 

This project combines the client’s material handling expertise with Airtight Solutions’ specialist knowledge in dust suppression technology. Unlike standard off-the-shelf solutions, the Dry Fog system is tailored to the specific material handling process and dust generation points. This allows the system to target dust at critical locations while minimising the amount of water introduced into the product stream. 

Targeted Dust Suppression at Key Transfer Points 

The custom-designed Dry Fog system will provide dust suppression across several treatment areas, including: 

• Infeed hopper at the first transfer point 

• Hopper discharge into the fines bin 

• Additional infeed hopper treatment areas 

Each treatment point has been assessed to determine the ideal nozzle configuration and fog coverage requirements. The systems are largely identical in design but operate independently, allowing each area to receive targeted dust suppression based on the specific operating conditions of that process point. 

How Dry Fog Dust Suppression Works 

Dry Fog dust suppression technology uses ultra-fine water droplets to capture airborne dust particles before they can disperse throughout the facility. 

When fog droplets come into contact with airborne dust, they attach to the particles and increase their mass, helping them return to the product stream. The technology is designed to use significantly less water than conventional wet dust suppression methods. For this application, the system requires compressed air and water at standard tap pressure. The combination of ultra-fine droplets and minimal water usage allows the system to provide highly effective dust control while adding less than 0.05% moisture to the product stream. This makes Dry Fog particularly suitable for material handling applications where maintaining product characteristics and minimising moisture addition are important operational requirements. 

Custom-Engineered Fogging Systems 

One of the key advantages of Dry Fog technology is its adaptability to individual applications. 

For this project, Airtight Solutions designed multiple systems incorporating manifolds fitted with strategically positioned fogging nozzles, along with individual nozzles installed in specialist adapters where required. The number and placement of nozzles have been carefully configured to provide optimal fog distribution throughout each treatment area. This customised approach ensures dust suppression occurs at the point of dust generation rather than relying on the broad application of water throughout the material handling process. 

Dry Fog for Industrial Dust Control 

Dry Fog technology can be applied across a wide range of industrial and material handling environments where airborne dust must be controlled effectively. 

Common applications include: 

• Material transfer points 

• Hoppers and hopper discharge points 

• Conveyors 

• Crushers 

• Screens 

• Recycling facilities 

• Resource recovery facilities 

• Processing plants 

• Waste management operations 

By designing each system around the unique characteristics of the application, Airtight Solutions delivers targeted dust control solutions that minimise water consumption while helping maintain product quality and operational efficiency. 

Delivering Custom Dust Suppression Solutions 

Investment in purpose-built dust suppression technology demonstrates how leading recycling and resource recovery operators are embracing innovative engineering solutions to improve operational outcomes. 

Airtight Solutions is proud to support major Australian recycling and materials handling operations with custom-engineered Dry Fog systems designed specifically for their process requirements. 

Looking for a custom Dry Fog dust suppression system for your industrial, recycling, waste management or material handling operation? 

Contact Airtight Solutions today to discuss your application.