OnAire with SonicAire

In this episode, we break down the real combustible dust explosions that happened in 2025 and 2026—and the hard lessons every facility needs to learn from them. These aren’t old case studies. These are recent incidents in grain, biofuel, and metal facilities—some resulting in injuries, fatalities, and devastating damage. The truth? Most of these events were preventable.   🔍 What We Cover: The 2025 grain dust explosion report (7 incidents, injuries up, fatalities up) Real incidents across: Grain elevators Feed mills & biofuel plants Metal dust facilities   What caused them: Overheated bearings Equipment maintenance failures Smoldering material Unknown ignition sources Why small and mid-sized facilities are increasingly at risk A recent North Carolina explosion and what we know so far   Dust accumulation + ignition source = explosion risk Even with dust collectors and cleaning crews in place, fugitive dust still escapes and builds up in overhead areas, where it becomes the most dangerous.   The Key Lesson: Prevention Beats Reaction   Many facilities rely on: Dust collection systems Manual cleaning Scheduled maintenance But these are often reactive rather than preventive.   That’s why more facilities are turning to engineered housekeeping solutions like Dynamic Particle Control (DPC), which continuously prevents dust from accumulating in the first place.   Why This Matters Behind every incident is a real cost: Lives lost Families impacted Teams forever changed   And the hardest part is that we know how to prevent these events.   What You Can Do Next   If you’re responsible for plant safety, operations, or maintenance: Take a hard look at your housekeeping strategy Don’t rely on dust collection alone Make sure your facility is truly compliant and protected   Learn More About Preventing Dust Explosions Visit 👉 https://www.sonicaire.com   Get a free facility evaluation and see how you can eliminate fugitive dust risks before they become incidents.   👍 If This Helped: Like & Subscribe for more real-world dust safety insights Share this with someone responsible for plant safety   Because the next incident doesn’t have to happen.

What does it take to build a company that helps prevent combustible dust disasters—not just clean up after them? In this special episode of OnAire, Taylor switches chairs and puts the spotlight on Jordan, SonicAire’s President and Owner, to share the story behind the mission. Jordan grew up in Reidsville, North Carolina, with grease under his fingernails—learning to fix machines the old-school way. That curiosity led him to mechanical engineering at NC State… then into forensic engineering, where he investigated real fires and explosions. From there, he worked at Underwriters Laboratories (UL) testing safety-critical equipment like firefighter rescue gear. Then came the turning point: Jordan joined SonicAire (15 years ago) and moved from “showing up after the incident” to helping customers prevent incidents in the first place. In this episode, you’ll hear: How SonicAire evolved from “Fan 1.0” to a stronger product and broader industries The hard truth about culture—and how SonicAire went from toxic → healthy → flourishing Why proactive service matters (install, repair, PM programs) What it means to lead with people first—and stay aligned as the company grows Where SonicAire is headed next (hint: more impact, more customers helped) If you’re asking questions like: “How do we prevent combustible dust risk, not just react to it?” “How do we grow without losing our culture?” “What does real safety leadership look like?” …this episode is for you. 👉 Learn more about SonicAire and how we help facilities reduce dust accumulation risk: sonicaire.com #CombustibleDust #ManufacturingSafety #IndustrialSafety #SafetyCulture #Leadership #UL #OSHA #NFPA #DustControl #SonicAire #OnAirePodcast

In this episode of OnAire, we kick off 2026 with a powerful conversation with Travis Davis, Operations Manager at a major grain elevator in Kansas. Travis shares how he helped develop and implement SonicAire’s first-ever Class II Division 1 certified fan for hazardous grain environments. If you’ve ever wondered: “Can a fan really help with dust in a grain elevator?” “Why hasn’t the grain industry adopted new dust solutions?” “How do I reduce manual housekeeping and increase uptime?” …this episode is for you. Hear Travis’s honest take on: How he helped push SonicAire to innovate for grain What it took to get internal buy-in for something new The real-world results they’re seeing after installation Why his crew now takes their dust-free environment for granted (and that’s a good thing) SonicAire’s fans are a proven technology in textiles, wood, paper, and now — thanks to people like Travis — agriculture. If you’re in grain handling or ag processing and fighting the uphill battle against dust, you’ll want to hear this. 🔧 Learn more at SonicAire.com 🎧 Subscribe for more industry stories, safety breakthroughs, and everything dust-related.

Featuring: Jana and Mark from Osprey, SonicAire’s trusted European partners in engineered dust control.   The Big Idea: Fans don’t always create dust clouds. SonicAire fan systems prevent them.   In this international episode of the OnAire Podcast, we sit down with our partners from Osprey, based in France, to explore a powerful truth: combustible dust control is misunderstood by regulators, insurers, and even safety professionals on both sides of the Atlantic.   Who Should Watch This Episode: Fire marshals and local AHJs Safety officers, plant managers, and EHS leaders Insurance auditors and risk assessors Professionals in grain, feed, wood, tobacco, paper, recycling, and other high-risk industries   What You’ll Learn: 1. US vs. Europe: Two Compliance Worlds, One Shared Challenge In the US, OSHA and NFPA (especially NFPA 652) guide combustible dust standards. In Europe, ATEX regulations govern explosive environments, but insurance companies often enforce standards more aggressively than local authorities. Across both regions, misunderstandings about fan-based dust control are common—and costly. 2. The Myth: Fans Stir Up Dust and Make Things Worse Some AHJs and insurers assume that fans increase fire and explosion risk by stirring up dust. In reality, SonicAire fans prevent dust accumulation in overhead and hard-to-clean areas by maintaining continuous airflow barriers. The result: no build-up, no dust clouds, no shutdowns. 3. The Reality: Fans Reduce Risk, Improve Compliance, and Restore Coverage Osprey shares how European customers—especially in wood and paper industries—have been able to: Avoid insurance cancellations Reduce costly manual cleanings Achieve ongoing OSHA and ATEX compliance Prevent secondary explosion hazards with cleaner overheads 4. What Happens When Insurers or Fire Marshals Say “No” to Fans This episode walks through real scenarios where inspectors shut systems down—only to reverse their decisions after being educated on how SonicAire fans work. With the right documentation, the conversation shifts from “this looks risky” to “this solves our problem.” 5. What Documentation is Available for Regulators and Insurers? SonicAire provides: Fan compliance letters Documentation that aligns with NFPA 662, Class II Div 1 and Div 2 ratings, and ATEX 22 certification Reference sites and real-world case studies to support approvals   Why This Episode Matters If you're a regulatory official, insurance decision-maker, or plant safety leader, and you’ve ever questioned the role of fans in a combustible dust environment, this conversation is essential. The idea that “fans cause dust clouds - not control them” is a myth. And in today’s risk-averse world, myths can lead to missed opportunities, higher costs, and increased hazards.   Watch This Podcast to Learn: Who thinks their compliance guidelines are tougher, the US or Europe? How insurance companies in Europe now recommend SonicAire systems. What makes NFPA/OSHA and ATEX perspectives similar—and different. Why prevention always beats reaction when it comes to dust compliance. How Osprey and SonicAire partner to help facilities educate regulators, retain insurance, and protect people   🎧 Listen now: sonicaire.com/on-aire-podcast 📩 Need help talking to an AHJ or insurer? Contact our compliance team.   This isn’t just another safety podcast. It’s a direct conversation with the people who’ve seen the misconceptions—and fixed them.

Can universities help prevent industrial explosions? In this episode of the OnAire Podcast, we sit down with Jonathan McPherson, an industry educator and dust safety expert from Kansas State University’s Powder & Bulk Solids Lab, to talk about real-world challenges in dust collection, fugitive dust, and how education is bridging the gap between theory and plant-floor reality.   🔎 Whether you're a safety manager, plant engineer, or facilities director, this is a conversation you don’t want to miss. We cover: ✅ What’s really happening with bulk solids and dust in today’s facilities ✅ Why even the best dust collection systems can’t do it all ✅ The role of Dynamic Particle Control in proactive housekeeping ✅ How SonicAire’s technology is transforming dust safety compliance ✅ The future of smart manufacturing & air quality monitoring ✅ Personal stories from the plant floor—and the farm!   📌 Key Takeaways: Fugitive dust is everyone’s problem – even in your garage. Education is catching up with what industry truly needs. Proactive dust control saves money, time, and lives. SonicAire fans help prevent fires, reduce labor, and improve air quality.   🧠 Why it Matters: You want a safer, cleaner, more efficient facility. But fugitive dust puts that at risk every day. In this episode, Jonathan shares how industry leaders and educators are partnering to create real solutions that work—today and tomorrow. You can be the hero of your facility's dust control story.   🔥 Want to Learn More? Visit https://www.sonicaire.com to see how our engineered dust control fans can: Eliminate overhead dust Reduce cleaning costs Improve OSHA and NFPA compliance Make your plant safer and healthier   🎧 Listen. Learn. Lead. Subscribe to the OnAire Podcast for more industry conversations that matter.

In this episode of the OnAire Podcast, we’re joined by Diane Cave, a powerhouse in the combustible dust world with 20+ years of experience helping facilities uncover and address hidden hazards. If you're a plant manager, engineer, or EH&S leader, this episode is your no-fluff, real-world guide to doing Dust Hazard Analyses (DHAs) right—and what happens when you don’t. TL;DR: A vague Dust Hazard Analysis isn’t harmless—it’s dangerous. In this episode, Diane Cave explains how language, leadership, and liability intersect in combustible dust safety. You’ll leave with tools to ask better questions, write stronger reports, and create a culture where safety isn’t a checkbox—it’s a commitment.   🎙️ What You’ll Learn: ✅ Why DHAs fail (and how to make yours actionable) ✅ The danger of “soft language” in safety reporting ✅ How insurers and regulators are driving DHA enforcement ✅ The right way to think about compressed air and blowdowns ✅ How safety culture shows up in the dust (literally) ✅ When your cleaning plan is actually failing ✅ Why clarity in a DHA isn’t just kind—it's critical   Diane also shares her infamous “dust lottery” analogy—and why some facilities are unknowingly buying tickets. "Every time you say 'should consider,' you're giving someone permission to ignore a hazard." – Diane Cave   🙋‍♂️ Who This Is For: This episode is made for manufacturing professionals who are: 🧠 Overwhelmed by combustible dust compliance 📋 Unsure what a DHA actually needs to say 🔎 Tired of vague language and unclear next steps 💬 Ready to improve internal safety communication 📉 Trying to reduce risk, downtime, and insurance headaches   ❓ Frequently Asked Questions (FAQ) Q: What is a DHA (Dust Hazard Analysis) and do I need one? DHA is a formal, systematic review of your facility's combustible dust risks and safety practices. If your process generates dust, you likely need one to comply with NFPA 652 and NFPA 660. Q: Who enforces DHAs? While OSHA and AHJs may spot-check, insurance providers and corporate risk departments are often the driving force behind DHA requirements. Q: What’s the risk of not doing a DHA? Beyond non-compliance, you risk property damage, production loss, employee injury, or worse. Inaction = liability. Q: How do I know if my DHA is any good? If it’s filled with “may,” “might,” or “should consider” language—it's not directing action. A solid DHA gives clear, prioritized, and enforceable recommendations. Q: Can I write my own DHA? It’s not recommended. Third-party experts, like Diane’s team at Element 6, bring technical insight, field experience, and unbiased clarity.   🔗 Resources & Contact: Learn more about Diane Cave and Element 6:   / diane-cave-p-eng-616b405   Explore SonicAire’s engineered dust control systems: https://www.sonicaire.com   👍 Like this episode? Hit like, subscribe, and share with your team. 🎧 Available wherever you get your podcasts.

What happens when a customer becomes part of your product development team? Meet Tommy Cocanougher, a 30-year veteran with Cintas and one of SonicAire’s longest “non-employee employees.” From dreaded Saturday lint blowdowns to helping co-develop the SonicAire portable fan, Tommy’s story is proof that innovation starts with listening to the people on the frontlines. In this episode of the OnAire Podcast, Tommy shares: How lint cleanings were a constant safety risk for laundry plants Why Cintas partnered with SonicAire to engineer a better solution The inside story of developing the Mobile/MobileFlex fan used across the industry today Why culture and safety must go hand in hand in every facility If you’ve ever wondered how SonicAire fans became the standard for dust control in laundry facilities, this is the episode to watch. ✅ Learn more about SonicAire Dust Control Fans: https://www.sonicaire.com ✅ Request your Free Engineering Assessment: https://www.sonicaire.com/contact ✅ Subscribe to the OnAire Podcast for more behind-the-scenes industry stories Dust is done.™ Together, SonicAire and leaders like Cintas are reshaping safety, efficiency, and compliance in dust-heavy industries.

🎙️ Back Where It All Began: Trade Shows, Tragedy, and Turning Points | OnAire Podcast   In this episode of the OnAire Podcast, hosts Jordan and Taylor take you behind the scenes of SonicAire’s recent return to The Clean Show in Orlando—one of the laundry industry’s premier events. From early memories at the booth in 2009 to partnering with major brands like Cintas, it’s a nostalgic look at how far SonicAire has come.   But this episode isn’t just about looking back. We also discuss a tragic combustible dust explosion in Nebraska that claimed three lives—including two young girls—and what the industry must learn from it. As safety leaders, we reflect on the heartbreaking reality that these events are preventable with the right systems and leadership mindset in place.   Plus, hear about: ✅ Why trade shows like The Clean Show are more than just marketing ✅ The power of relationships in product design ✅ Our work with Kansas State University to train the next generation of dust control experts ✅ How your facility’s culture is shaped by your safety investments ✅ A sneak peek at upcoming episodes and industry insights   This episode is packed with real talk, real stories, and real purpose. If you're passionate about creating safer, healthier, and more efficient workplaces, this one’s for you.   🧡 Let’s work together to make sure no more lives are lost to preventable dust incidents.   📌 Links & Resources: 👉 Learn more about SonicAire’s Dust Control Fans: https://www.sonicaire.com 👉 Want to attend the Fundamentals of Dust Collection class? Check out Kansas State’s Advanced Manufacturing and Bulk Solids Technology Center. https://olathe.k-state.edu/research/advanced-manufacturing-bulk-solids-technology-center/ 👉 Need help with your facility? Talk to a SonicAire Dust Control Specialist today. https://www.sonicaire.com/parts-and-service-2/ 🔔 Don’t forget to Like, Subscribe, and Share this episode to help spread awareness about combustible dust hazards and how to stop them before they start.

🎧 OnAire Episode 7 | Real-World Lessons in Safety Culture and Change How do you turn safety from a checklist into a shared mindset? In this episode of OnAire, we sit down with the Environmental Health and Safety Manager of a leading building materials distributor that specializes in doors and millwork. He shares how he helped lead a cultural shift across multiple locations by starting with people, not policies. He did not force compliance. He built relationships first. From working the production floor to riding along with delivery drivers, this safety leader focused on trust and understanding before introducing change. His approach proves that real progress in safety comes from listening and aligning, not just checking boxes. If you are a safety professional, plant leader, or operations manager trying to create lasting change, this episode gives you the real playbook. 💬 What you will learn: ✅ Why safety initiatives often fail and how to gain real buy-in ✅ What to focus on in your first 30 days as a new safety leader ✅ How to connect safety goals to operational priorities ✅ The mindset shift that made safety part of the company culture ✅ A simple way to link safety to quality, efficiency, and trust 🧠 Quote to remember: "If we are going to do something for safety, it has to help quality, efficiency, or the work environment too." This episode is not about selling a product. It is about what it takes to lead meaningful change inside a busy, high-demand facility. You will walk away with insights that apply in any industry and any organization. 🔗 Find more episodes and resources at sonicaire.com/podcast

Are you a plant manager dealing with combustible dust? In this episode of the SonicAire OnAire podcast, Jordan and Taylor break down the Top 4 Dust Control Essentials you need to know to keep your facility safe, compliant, and productive. They’ll cover: ✅ How to spot and manage fugitive dust ✅ What your dust collector is (and isn’t) doing for you ✅ Why documentation like DHAs and housekeeping plans matter ✅ What NFPA 660 means for your plant and how to tackle it with confidence You’ll also hear some fun behind-the-scenes stories about growing up in Reidsville, NC, because every expert has a hometown, and every safety plan has a starting point. 👉 Whether you're just getting started or need a gut check on your current strategy, this episode will give you real, actionable advice straight from the dust control experts. 🔗 Learn more at https://www.sonicaire.com 📞 Ready for help? Contact us to start your engineered dust control plan. Like, subscribe, and leave a comment with your biggest dust control challenge—we’d love to help!

This one’s more than a podcast—it’s a story of how a mission trip, a tragic accident, and a plane ride over the Gulf of Mexico led to a better way to serve our customers. In this episode of the OnAire Podcast, we sit down with Rob Nelson, Director of Services at SonicAire, and unpack the wild, winding journey that shaped how we show up for our customers today. You’ll laugh (think gator metaphors and old church photos), you’ll get inspired (real talk on change management), and you’ll learn: Why great service means more than fixing what’s broken How proactive maintenance helps customers avoid costly surprises Why your dust problem should never be your problem And yes, what SonicAire’s chatbot is named (hint: it's very on brand) 👀 BONUS: Watch the full video to see the 20-year-old photos from Rob and Jordan’s mission trip to Mexico that sparked a lifelong connection—and an entirely new approach to customer care. ➡️ Want to work with a team that actually gets what you’re dealing with? Head to https://www.sonicaire.com and let’s solve your dust challenge—for good.

Grain dust explosion caught on camera. Five injuries. No fatalities. But what if the next one is worse? In this episode of OnAire, Jordan and Taylor break down a recent explosion at a grain facility in Sunray, Texas and discuss what really causes these events and why the secondary explosion is often the most devastating part. You’ll also hear: ✅ What the new NFPA 660 standard means for dust safety ✅ How one moment of dust buildup can trigger disaster ✅ A surprising student-led dust explosion experiment using coffee creamer ✅ Real talk on tariffs, pricing pressure, and how SonicAire is staying committed to customer safety ✅ What it’s like to be on the NFPA Combustible Dust Technical Committee If you work in grain, ag, food, or any industry dealing with combustible dust, this episode is a must-watch. Dust is no joke. Seconds matter. And standards are changing. Stay with us to the end for a big-picture look at where the dust safety world is going next—and how you can stay ahead of it.

Welcome back to the OnAire Podcast, where we dig into all things fugitive dust – that fine, floating troublemaker that sneaks away from your process and creates big risks in hard-to-reach places. In this episode, we’re joined by Jerry Peters, a 30-year safety veteran and former recycling industry pro, who shares real-world insight into the challenges of combustible dust – and how he tackled them with SonicAire Dust Control Fans. 👷‍♂️ Jerry spent over two decades in glass recycling and MRFs (Material Recovery Facilities), dealing with the constant dust that builds up in overhead spaces, causes safety concerns, and adds costly labor. From OSHA inspections to game-changing installations, Jerry walks us through the before-and-after of bringing SonicAire fans into his plant—and how it slashed cleaning time, improved air quality, and helped them stay compliant. 🔥 Topics We Cover: What really happens when OSHA shows up for a combustible dust inspection The true cost of manual overhead cleaning Why SonicAire fans don’t just blow dust around—they stop it from building up A hilarious (and true) story about dust so thick, you couldn’t see 5 feet ahead The science behind Dynamic Particle Control (DPC) Can greasy pizza boxes be recycled? (Spoiler: YES!) 🍕 Plus, we find out what it’s like reffing arena football and working side-by-side with the real gatekeeper of knowledge—Jerry’s wife. 🔧 Learn how SonicAire’s BarrierAire™ Technology proactively keeps dust out of the air and off your overhead surfaces: https://www.sonicaire.com

Dust collection is only half the battle! In this episode of OnAire by SonicAire, we dive deep into the evolution of dust management with Chuck Morrison, VP of Sales at SonicAire. Discover the critical difference between dust collection vs. fugitive dust control—and why ignoring airborne dust could put your facility at risk.   🔥 Topics covered: ✅ The history & future of dust management ✅ The biggest misconception about dust control fans ✅ How modern innovations like agglomeration are changing the game ✅ Why dust control is about more than just compliance—it’s about safety   Don't miss out! Like & Subscribe to stay ahead of industry trends.

Is your facility at risk for combustible dust hazards? SonicAire has spent years developing cutting-edge fan technology to prevent dust buildup—and now, our newest fan is Class II, Division 1 certified. But getting that certification wasn’t easy. In this episode, Jordan sits down with Taylor Andrews, SonicAire’s Director of Operations, to pull back the curtain on the three-year battle to meet UL’s strict standards. You’ll hear: 🔥 Why some facilities must have Class II, Division 1 certified equipment 🔥 The unexpected hurdles SonicAire faced (including endless rounds of testing) 🔥 How this new certification opens doors for safer operations in industries like grain, feed, and manufacturing 🔥 What’s next for dust control innovation This is a must-listen if you want to stay ahead of safety regulations and protect your facility. 🎧 Listen now and subscribe! #SonicAire #OnAirePodcast #CombustibleDust #IndustrialSafety #OSHA #NFPA #ManufacturingInnovation