OnAire with SonicAire

SonicAire
  • 5.0 (1)
  • Business
  • Updated Biweekly

A new podcast on all things fugitive combustible dust. Join Jordan Newton, P.E., in a discussion of all things combustible dust related.

  1. 5d ago

    OnAire Episode 20: Why Combustible Dust Explosions Still Happen—and How to Prevent Them - with Dr. Kingsly Ambrose

    Can combustible dust explosions actually be prevented? In this episode of the OnAire Podcast, Jordan and Taylor sit down with Dr. Kingsly Ambrose of Purdue University to talk about combustible dust explosions, grain facility safety, fugitive dust, and what manufacturers can do to reduce risk. Dr. Ambrose studies particle technology and dust explosions and compiles annual data on combustible dust incidents. His goal is one we can all get behind: reaching a year with zero explosions, zero injuries, and zero deaths. But getting there takes more than equipment. 🔥 *What is one of the most important ways to prevent a combustible dust explosion?* Start by keeping the facility clean. Dr. Ambrose explains that preventing deposited and suspended dust from building up is a critical first step. From there, facilities need employee and contractor training, warning systems, explosion protection, and a safety culture where unusual noises, smells, or other warning signs are never ignored.

  2. Aug 27

    Is Safety A Priority or a Value? - with Kevin Jeffries

    Safety works best when it is more than a priority. It needs to be part of how your plant operates every day. In Episode 19 of the OnAire Podcast, Senior Explosion Safety Consultant Kevin Jeffries shares lessons from 30 years in EH&S, including firsthand experience with facilities impacted by major explosions. He explains why combustible dust safety starts with understanding real-world risk, listening to the people doing the work, and designing processes that make the safe choice the easy choice. The conversation explores safety culture, dust explosion prevention, leadership, and why EH&S should be a partner in production, not just the department called when something goes wrong.

  3. Jul 30

    Combustible Dust Housekeeping: Real Lessons From 15 Years in Manufacturing - with Darrell Cloudt

    What can more than 15 years and over 1,000 industrial dust control fan installations teach you about combustible dust housekeeping? In this episode of the OnAire Podcast, Jordan and Taylor sit down with Darrell Cloudt of Energy Solutions of Texas, one of the most experienced SonicAire installers in the world. From wood products and plastics to grain processing and food manufacturing, Darrell has seen firsthand what works, what doesn't, and what manufacturers often overlook. They discuss why overhead dust is usually worse than plant teams expect, why pre-cleaning is critical to long-term success, and how communication between contractors and facility teams can make or break an installation. Darrell also shares stories from challenging projects, including towering grain facilities, hazardous Class II Division 1 environments, and facilities where preventive maintenance made the difference between reliable performance and costly downtime. Whether you're a plant engineer, maintenance manager, operations leader, or EH&S professional, this conversation is full of practical advice you can apply in your facility today. In this episode: • Why combustible dust is often hiding where no one is looking • The importance of pre-cleaning before installing a dust control system • Common installation mistakes and how to avoid them • Why preventive maintenance protects your investment • Lessons learned from more than 1,000 industrial fan installations • How facilities improve housekeeping without increasing labor Featured Quote: "It's a lot worse than you think it is. Every time you do a startup, they realize you were right." Learn more about SonicAire's engineered dust control solutions: 👉 https://www.sonicaire.com

  4. Jul 28

    The Grain Industry Has a Dust Problem — And It’s Completely Preventable - with Steven Kilger

    The grain industry has a dust problem — and according to Feed & Grain editor Steven Kilger, it’s completely preventable. In this episode of the OnAire Podcast, we sit down with Steven Kilger, Managing Editor of Feed & Grain magazine, to talk about the real challenges facing grain and feed facilities today: Combustible dust hazards Labor shortages Grain storage limitations Automation and AI in agriculture Why do preventable accidents still happen The future of feed & grain operations Steven brings a unique perspective as someone who has spent more than a decade covering the grain industry from the inside. From dust explosions and housekeeping challenges to the future of technology in agriculture, this conversation dives deep into the realities manufacturers and processors are facing right now. If you work in grain handling, feed manufacturing, agriculture, or industrial dust control, this episode is packed with practical insight and honest conversation. Subscribe for more conversations around combustible dust, industrial safety, manufacturing, and automation. Learn more about SonicAire dust control solutions: https://www.sonicaire.com Connect with Feed & Grain: https://www.feedandgrain.com

  5. Jun 25

    The Hidden Risks of Combustible Dust: Lessons from the Maine Explosion - with Alec Brenchley

    What causes combustible dust explosions, and how can manufacturers reduce their risk? In this episode of the OnAire Podcast, Jordan and Taylor discuss the recent combustible dust explosion at a wood processing facility in Maine that resulted in multiple injuries and the tragic loss of two first responders. The conversation explores why combustible dust remains a serious hazard across industries, including wood products, grain handling, and metal processing. The hosts emphasize the importance of combustible dust hazard assessments (DHAs), proactive dust control strategies, and maintaining compliance with NFPA standards and OSHA regulations. The episode also features SonicAire licensed electrician Alec Brenchley, who shares his journey into the electrical trade and explains how SonicAire's turnkey installation services help manufacturers simplify combustible dust mitigation projects. Alec discusses electrical compliance, classified locations, permitting, installation challenges, and how proper system design helps facilities maintain safe and compliant operations. Topics Covered: • Recent combustible dust explosion in Maine • Why combustible dust incidents impact entire communities • NFPA and OSHA combustible dust compliance • What is a Dust Hazard Analysis (DHA)? • Electrical requirements for dust control systems • Class II Division 1 and Class II Division 2 environments • Turnkey dust control system installation • Common challenges in industrial dust control projects • How facilities can improve combustible dust safety If you're searching for answers about combustible dust prevention, combustible dust compliance, industrial dust control systems, overhead dust accumulation, dust hazard analysis requirements, or how to reduce combustible dust explosion risks, this episode provides practical insights from industry professionals working in the field every day. Learn more about fugitive dust control and combustible dust safety at http://www.sonicaire.com.

  6. Mar 31

    2025–2026 Dust Explosions Breakdown: Real Incidents, Real Lessons

    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.

  7. Feb 26

    From Fire Scenes to Prevention: Jordan’s Story, and Why SonicAire Exists

    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

  8. Jan 30

    Can a Fan Really Prevent Dust Explosions? This Grain Ops Manager Says Yes. - with Travis Davis

    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.

See All (20)

About

A new podcast on all things fugitive combustible dust. Join Jordan Newton, P.E., in a discussion of all things combustible dust related.

Information

  • Creator
    SonicAire
  • Years Active
    2025 - 2026
  • Episodes
    20
  • Rating
    Clean
  • Copyright
    © Copyright 2025 All rights reserved.
  • Show Website
    OnAire with SonicAire