Background

The client is a long-established Western Australian agribusiness operating a grain feed processing facility supplying pelleted feed to livestock producers.

The site handles large volumes of grain via conveyors and transfer points, creating an inherent risk of explosive airborne dust generation within enclosed processing areas.

Situation

A hazardous area inspector was engaged by the client to complete a formal safety assessment after a potential dust risk was identified within the facility.

Due to the combustible nature of grain dust, the inspection triggered further involvement from electrical contractors, engineers, and safety specialists.

The assessment identified airborne dust as a potential explosion hazard and recommended the implementation of a dust control solution. Traditional compliance pathways would have required significant upgrades, including explosion-rated equipment, specialised electrical fixtures, and extensive operational and maintenance changes.

The client contacted Dust-A-Side Australia after researching effective and practical dust suppression solutions suitable for grain handling environments.

A key constraint was moisture control as grains exposed to excess moisture can become mouldy, making conventional wet suppression methods unsuitable.

BEFORE

Solution

Dry fogging was identified as the most appropriate solution, as it introduces minimal moisture while effectively controlling airborne dust.

The system operates using low-pressure nozzles that combine air and water, with the air atomising the water into ultra-fine droplets measuring less than 5–10 microns. This delivers just enough moisture to knock dust out of suspension without wetting the grain or surrounding infrastructure.

Dust-A-Side Australia developed the system design, while the client constructed the installation based on the design for a minimal cost. The system was fully automated and linked directly to the grain conveyor operation. When grain unloading occurs, the dust suppression system activates automatically, runs for a set duration, and then shuts down.

Dust-A-Side Australia supplied the specialised nozzles, which were installed by the client.

Commissioning and Challenges

The dust suppression system was retrofitted into an existing building, requiring careful design and nozzle placement to maximise dust control effectiveness while avoiding disruption to ongoing operations.

Maintainability was a key consideration from the outset. As with all dust suppression systems, nozzle blockages are inevitable over time, making routine inspection and maintenance essential. To address this, the nozzles were supplied with integrated clean-out needles, allowing for quick and easy clearing, reducing maintenance time and minimising operational downtime.

Despite the constraints of the existing infrastructure and access limitations, the system was successfully commissioned and fully integrated into daily operations, delivering reliable and consistent dust control performance.

AFTER

Results

• The hazardous area classification zone was reduced, improving overall site safety
• Airborne dust levels were significantly reduced at the source
• Explosion risk was mitigated without the need for major capital upgrades
• The client avoided costly investments in explosion-rated equipment, specialised fixtures, and extensive maintenance
• The solution delivered improved safety outcomes with minimal operational disruption

The client was satisfied with the performance of the system and is in the process of expanding the dust suppression solution into additional areas of the facility.

Conclusion

In grain processing environments, airborne dust presents a serious explosion hazard, often requiring extensive and costly compliance measures.

By implementing a targeted dry fog dust suppression system, the client effectively controlled dust at the source, reduced explosion risk, and avoided significant capital expenditure.

The outcome delivered measurable safety improvements, operational efficiency, and long-term cost savings.

If your facility faces dust hazards or compliance challenges, contact Dust-A-Side Australia to explore practical, cost-effective dust suppression solutions

Click here to request a consultation. Or give us a call on 1800 662 387.