Providing Cost Savings and Safety Improvements to an Aircraft Manufacturer
Total Filtration Services
Unified ROI Framework
Switching from calendar-based to gauge-driven filter changes reduced aerospace sanding table filter costs by 83% — from $73,483 to $12,247 annually — while reducing hazardous dust exposure and downtime across 18 tables
Direct ROI
Total Documented
$61,235 annually
Filter Savings
$61,235 annual savings (from $73,483 down to $12,247.20)
Labor Savings
5 out of 6 monthly changeouts eliminated — filters now last 6 months average
Waste Reduction
83% reduction in hazardous dust-contaminated filter disposal fees
Operational Excellence
Downtime
Reduced production downtime from monthly filter change procedures across 18 sanding tables
Safety
Dramatically reduced hazardous dust exposure — fewer changeouts means significantly less worker contact with metal dust-laden filters on sanding and grinding tables
Soft Savings
$61,235 in direct annual savings documented; additional safety compliance value substantial
Facility Efficiency
Equip Life
Proper gauge-based monitoring prevents over-changing (waste) and under-changing (equipment clogging)
Maintenance
6x reduction in filter changeout frequency across 18 tables
ESG Overlay
Gauge-driven filter management delivers 83% reduction in hazardous sanding dust filter waste while dramatically improving worker safety through reduced exposure during changeouts
Sustainability
83% reduction in filter consumption for hazardous dust applications — significant material and waste reduction
Waste
83% reduction in hazardous waste filter disposal — significant regulatory compliance improvement and cost avoidance
The company involved in this case study manufactures small military and jet driven aircraft, as well as tires, TFS customer for many years.
Challenge
The customer had been changing filters on their sanding/trim and grinding small parts tables on a monthly basis, which consisted of 18 tables and a total of 108 filters.
The frequency of these change-outs resulted in:
Filter replacement costs of approximately $73,483
Significant production downtime
Excessive levels of hazardous waste exposure and disposal expenses
The TFS Solution
A TFS filter expert surveyed the units on the customer’s shop floor to confirm the magnehelic gauges were functioning properly. TFS found that the tables were reading in the manufacturer’s acceptable filter pressure drop range.
TFS then met with maintenance supervisors and shop floor foreman’s and explained the proper filter change-out procedures based on magnehelic gauge readings.
The sanding table manufacturer recommended that filter change-outs occur when the level is 4”.
New filters read 1.8”, the tables that TFS was asked to change filters on were reading 2” (just above new filter level).
TFS recommended that table operators have a maintenance work order written to change filters when the filters reached 4” so they would be changed out as needed.
The customer followed TFS recommendations; sanding tables are now changed on a work order basis that gives the customer a true basis for when their sanding table filters need to be changed. On average, a sanding table filter will last 6 months.
Change-outs driven by magnehelic gauge readings
$12,247.20 spent on sanding table filters, providing a cost savings of 83%
Reduced downtime, labor, and disposal costs due to the change-outs occurring every 6 months.
Employees are at less risk of exposure to hazardous materials.
