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Thermal Spray

Donaldson Torit® dust collectors are in hundreds of thermal spray applications worldwide. Our advanced Ultra-Web® nanofiber filtration technology is supremely suited for applications involving thermally generated fume, especially when installed in a Donaldson Torit dust collector selected for your application.

Thermal Spray or Metalizing is a group of coating processes which deposits finely divided metallic or non-metallic materials in a molten or semi-molten condition on a surface/substrate to form a coating. The coating material may start out in the form of a powder, ceramic rod, wires, or even molten materials. The process has the potential to generate very small particulate often referred to as “fume”.  This thermally generated fume can be smaller than one micron in diameter, and uniform in size making collection a challenge.

Products for Thermal Spray


Donaldson Torit® advanced-technology cartridge dust collectors and a variety of filter media that conquer the challenges of most types of industrial dusts, including pharmaceutical, chemical, grain, bulk/powder, food, metal and others. ​​​

Downflo® Evolution

The best-in-class Downflo® Evolution (DFE) dust collector is capable of reducing equipment size and number of required filters by up to 40% compared to a typical cartridge collector.

Downflo® Oval

The high performance Downflo® Oval (DFO) family of dust collectors provides up to 25% more filtration capacity than other same-sized cartridge collectors.


Torit® PowerCore® dust collection technology use proprietary Ultra-Web nanofiber technology​, which allows for a smaller, more efficient filter, reducing the overall footprint of the dust collector.

PowerCore® TG Series

Designed for thermally generated dust with a footprint up to 65% smaller than most other cartridge collectors.

Thermal Spray Coating Process

Powder Feedstock -> Powder Particle Melting (Gas or Electric Heating) -> Molten Particle Acceleration -> Particle / Substrate Impact -> Coating

Processes Involving Thermal Spray

The thermal spray processes involves such heat that the process produces a very fine dust (fume), typically sub micron in size and very uniform. Some of the materials used in thermal spray applications have associated adverse health effects, and defined minimum exposure limits set for them, which necessitates effective dust collection.

Following are terms for typical thermal spray processes that produce fumes needing to be controlled:

  • Flame Spray                   Powder Flame Spray    
  • Wire Flame Spray          High Velocity Oxy / Fuel Spraying (HVOF)  
  • Cold Spray                      Plasma Arc Spray
  • Electric Arc Spray

Related Processes Producing Contaminants—Surface Preparation and Finishing Operations

  • Abrasive blasting
  • Grinding
  • Wet machining

Special Considerations

Many metal fume dusts are combustible and those operations generating or handling metal fumes can require special mitigation efforts to minimize fire and explosion risks. Standards such as NFPA 654 can provide guidance for those who generate and handle these types of dusts. See the Donaldson Dust Collectors and Combustible Dust Strategies brochure.

Metal fume dusts may also have identified adverse health impacts, and special mitigation strategies may be required to limit occupational exposure below levels OSHA or other health organizations have established for these materials.


Model: DFO 3-36 with 36 Cyclone Pre-Separator
Application: Electric Arc Thermal Spray
Location: Ohio

Model: Downflo Oval (DFO) 4-16
Application: Metallizing
Location: Mexico

Model: (7) DFT 4-48
Application: Plasma Arc Spraying
Location: California

Model: Downflo Oval (DFO) 3-18
Application: Powder Flame Spraying
Location: Oklahoma

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Falmer wanted overspray collection systems that would align with a green approach and grow with the company.

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