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Implementing Efficient Solutions: Safeguarding Your Workforce From Health Risks Due To Oil/Coolant Mist.

Oil & Coolant Mist
Oil & Coolant Mist Blog

Implementing Efficient Solutions: Safeguarding Your Workforce From Health Risks Due To Oil/Coolant Mist.

Oil and coolant mist exposure in the industrial environment is a serious health concern for workers nowadays. Every industry working in the area of metalworking and machining has been involved in such an exposure environment. Through this article, we'll look at some effective solutions for protecting workers from health risks caused by oil or cooling mist.

What is an oil mist?

Oil mist is the drizzle, which is made of droplet particles above 1 mm in size. Oil mist is created when oil emissions are used as a lubricant during the machining of metals.

There are two main types of oil mist:
  • Water-based: easier to collect but harder to remove from the air.
  • Oil-based: harder to collect but easier to remove from the air.

Oil Mist Illustrative Image

What is Coolant Mist?

Coolant mist is a mix of coolant and cold air. The coolant mist is used for spraying it on the cutting or machining operations of workpieces.

Types of Coolant Mist:

There are basically three types of coolant mist:

  • Soluble oils: This is a type of coolant mist that is a mixture of oil and water with special chemicals to be used as an emulsion.
  • Synthetic Fluids: This is an organic fluid originated from the synthesis of oils of animal, plant, or mineral origin.
  • Semisynthetic Fluids: It is a mix of conventional and synthetic fluids. It’s made by mixing synthetic and mineral fluids in a ratio of 25:75 to 35:65. The blend helps resist oxidation and withstand high temperatures. It also maintains the right viscosity at both high and low engine temperatures.

Health Effects of Oil Mist on Workers:

Machining oil mist is a common by-product of various industrial processes that involve metal cutting, grinding, and milling. This mist can pose a significant risk to human health if it is not properly controlled or handled. Exposure to machining oil mist can result in a variety of adverse health effects, ranging from minor irritations to serious respiratory problems and cancer.

Immediate Symptoms of Inhaling Oil Mist:

One of the most immediate effects of exposure to machining oil mist is irritation of the eyes, nose, and throat. This irritation can cause symptoms such as burning, itching, and watering of the eyes, as well as sneezing, coughing, and a sore throat. These symptoms may be short-lived, but they can still be uncomfortable and disruptive to work.

Major Effects of Oil Mist on Health:

In addition to these acute symptoms, prolonged exposure to machining oil mist can cause chronic respiratory problems. This mist can enter the lungs and cause inflammation, leading to conditions such as bronchitis and asthma. These conditions can cause difficulty breathing, wheezing, and coughing, making it harder for workers to perform their job duties.

Long-term exposure to machining oil mist has also been linked to an increased risk of lung cancer. The mist contains a variety of harmful chemicals, such as formaldehyde, benzene, and polycyclic aromatic hydrocarbons (PAHs), which are known carcinogens. These chemicals can accumulate in the lungs over time, increasing the risk of cancer.

According to a study and research report published in MDPI’s international journal of environmental research and public health, oil mist exposure can lead to reproductive effects in pregnant workers, which means heavy oil mist exposure can be the main reason behind birth defects and heart defects. You can read more about it here.

Factors Responsible for Exposure to Oil Mist:

The effects of machining oil mist exposure can vary depending on a number of factors, such as

  • The type and amount of mist
  • The duration
  • frequency of exposure,
  • The individual’s susceptibility to the chemicals in the mist

Some people may be more sensitive to these chemicals than others and may experience more severe symptoms or health effects.

How can we minimize the risks of oil mist exposure and prevent workers from getting it?

To minimize the risks associated with machining oil mist exposure, it is important to take appropriate precautions in the workplace.

  • Using ventilation systems to control the spread of mist,
  • wearing protective gear such as masks, goggles, and PPE.
  • implementing safe work practices to reduce exposure. 
  • Regular monitoring of air quality and worker health
  • Machining oil mist collectors plays an important role in protecting health as well as enhancing their productivity.

Why Oil Mist Collectors Are Important:

Machining oil mist collectors are essential tools in many industries where metal cutting and grinding are commonly performed. These devices are designed to capture and remove oil mist and other airborne contaminants from the workplace, improving air quality and protecting the health and safety of workers. There are several types of machining oil mist collectors available, each with its own strengths and weaknesses.

Types of oil/coolant mist collectors:

There are three types of technologies, i.e., mist collectors, available, namely:

  • Electrostatic precipitators(ESP)
  • centrifugal mist collector and
  • Media type filtration

Electrostatic precipitators (ESP)

Working Principles Behind Electrostatic Oil Mist Collectors

Electrostatic oil mist collectors use a high-voltage electrical charge to ionize oil mist particles as they pass through the device. The charged particles are then attracted to a grounded collector plate, where they are deposited and removed from the air stream. The ionization process is highly effective at removing oil mist particles from the air, and the collected oil can be easily recovered for reuse or disposal.

Electrostatic oil mist collectors are highly effective devices used in industrial settings to remove oil mist and other airborne contaminants from the air. They work by using an electrostatic charge to attract and capture oil mist particles as they pass through the device. Electrostatic oil mist collectors offer several technical advantages and benefits compared to other types of mist collectors.

ESP Working for Oil and coolant mist
Ball Point Tips Making Fume and Mist Collection System

Technical Advantages of Electrostatic Oil Mist Collectors

High Efficiency

Electrostatic oil mist collectors are highly efficient at removing oil mist particles from the air, with efficiency rates of up to 99%. This makes them highly effective at maintaining a clean and safe working environment for employees.

Low Maintenance

Electrostatic oil mist collectors require minimal maintenance compared to other types of mist collectors. They do not require frequent filter changes or cleaning, and the collected oil can be easily recovered for reuse or disposal.

Energy Efficient

Electrostatic oil mist collectors are highly energy-efficient, requiring only a small amount of power to operate. This makes them cost-effective and environmentally friendly.

Space-Saving Design

Electrostatic oil mist collectors are typically compact in size and can be easily integrated into existing equipment or workspaces. This makes them ideal for use in small or crowded work environments.

Benefits of Electrostatic Oil Mist Collectors

Improved air quality

Electrostatic oil mist collectors help to improve air quality in the workplace by removing oil mist particles and other airborne contaminants. This can reduce the risk of respiratory problems and other health issues for employees.

Enhanced Safety

Removing oil mist particles from the air can also enhance workplace safety by reducing the risk of slips, falls, and other accidents caused by oily floors and surfaces.

Increased Productivity

A cleaner and safer working environment can help increase employee productivity by reducing absenteeism and improving morale.

Cost Savings

Electrostatic oil mist collectors can help reduce operating costs by minimizing the need for expensive replacement filters and reducing maintenance and cleaning costs.

Electrostatic oil mist collectors are highly efficient devices that offer several technical advantages and benefits compared to other types of mist collectors. They work by using an electrostatic charge to attract and capture oil mist particles from the air, and they require minimal maintenance and energy to operate. By using an electrostatic oil mist collector in your workplace, you can improve air quality, enhance safety, increase productivity, and reduce operating costs.

Centrifugal Working for oil and coolant mist
Coolant Mist Collector For HMC and VMC

Centrifugal Mist Collectors

Centrifugal mist collectors use centrifugal force to separate oil mist particles from the air stream. As the air enters the collector, it is spun at high speed, causing the oil mist particles to move to the outer edge of the device. The particles then collect on a series of baffles or vanes and are removed from the air stream. Centrifugal mist collectors are effective at removing oil mist, but they may require more maintenance than electrostatic precipitators.

Media-Type Filtration for oil and coolant mist
Filter ON ESP Solution for oil and coolant mist

Media Type: Filtration

Media filtration involves passing air through a filter media that captures oil mist particles as they pass through. The filter media may be made of materials such as fiberglass or polyester, and it may be coated with an oil-absorbing material to improve its effectiveness. Media filtration is a common type of mist collection, and it is effective at removing oil mist particles, but it may require frequent filter replacement to maintain its effectiveness.

Government regulations on controlling oil mist exposure

The OSHA Occupational Safety and Health Administration has two permissible exposure limits (PELs) for air contaminants that apply to metalworking fluids (MWFs), i.e., oil and solvent mist:

  • Mineral oil mist: 5 milligrams per cubic meter (mg/m3) for an 8-hour, time-weighted average (TWA)

  • Particulates Not Otherwise Classified (PNOC): 15 mg/m3 for an 8-hour time-weighted average (TWA)

OSHA also requires vent lines at lubrication points to collect stray mist. You can see the different OSHA standards on this page. Click here to view them.

The Indian government’s Factory Act also follows these standards to control oil and coolant  mist exposures in India.

OSHA’s Best Practices to Control Oil/Coolant Mist Exposure:

OSHA has developed some best practices to control oil mist exposure; some of them are as follows:.

  • Obtain Safety Data Sheets (SDSs) from the supplier to know what precautions are recommended.

  • Choose MWFs with the least toxic materials when possible.

  • Maintain proper use of biocides.

  • Keep machines clean and change MWFs as necessary.

  • Use properly designed MWF delivery systems that minimize the amount of fluid mist generated.

You can view the other OSHA best practices by clicking here.

You can also refer to the OSHA best practice manual to understand the risks associated with exposure to oil or coolant mist. Click here to view it.

When do you require an oil/coolant mist collector for your organization?

Oil and solvent mist collectors are adding greater value to your entire machining work environment. They can be a very good asset for your company if you face the following three major problems:

  • The amount and exposure of oil or coolant mist are greater than the standard limits.

  • The affection rate percentage of mist to workers’ health is high.

  • The acceptance rate of production is higher than the average production.

Which is the right oil/coolant mist collector for your organization?

Choosing the right mist collector for your organization is an important task for you as they provide value to the entire work environment, so choosing the right mist collector involves the following factors:

  • Exposure to mist

  • Type of mist

  • Production area and types of machines used

  • Budget and future requirements

Filter On India can help you by carefully analyzing your exact requirements and giving you the proper guidance in choosing the right oil or mist collector for your organization

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune, or mail us at : marketing@filter-on.com

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Welding Fumes: Unveiling Hazards and Crafting Solutions For Safer Workforce

Welding Fumes: Hazards and Safety Solutions for Workers
Welding Fumes: Hazards and Safety Solutions for Workers

Welding Fumes: Unveiling Hazards and Crafting Solutions For Safer Workforce.

Welding joins materials together by melting a metal workpiece along with filler metal to form a strong joint; thus, welding is one of the most important fundamental processes in every industry. The welding process required in creating structures, making products, and fabricating them to make them safer involves joining various components, so it involves various particles to play with. When we talk about metalworking industries, welding plays a vital role in every step of the industry, so in the metalworking industry, welding is a very important process. In this article, we will discuss welding, welding fumes, their adverse effects on the workforce, and safety solutions to overcome welding fumes.

Types of welding:

Welding is classified into two groups: fusion (heat alone) or pressure (heat and pressure) welding. There are three types of fusion welding: electric arc, gas, and thermit. Electric arc welding is the most widely used type of fusion welding. It employs an electric arc to melt the base and filler metals. Arc welding types, in order to decrease fume production, include:

Gas or oxy-fuel welding uses a flame from burning a gas (usually acetylene) to melt metal at a joint to be welded and is a common method for welding iron, steel, cast iron, and copper. Thermit welding uses a chemical reaction to produce intense heat instead of using gas fuel or electric current. Pressure welding uses heat along with impact-type pressure to join the pieces. Oxy-fuel and plasma cutting, along with brazing, are related to welding as they all involve the melting of metal and the generation of airborne metal fumes. Brazing is a metal-joining process where only the filler metal is melted.

What are welding fumes?:

When the welding process runs in industries, it spreads various hazardous particles on the surfaces as well as in the air, such as metals like aluminum, antimony, arsenic, beryllium, cadmium, chromium, cobalt, copper, iron, lead, manganese, molybdenum, nickel, silver, tin, titanium, vanadium, and zinc. gasses like argon, helium, nitrogen, and carbon dioxide. Which is very dangerous and hazardous for the health of the workforce.

Health impacts on the workforce:

Short-Term Health Impact:

Acute exposure to welding fumes and gasses can result in eye, nose, and throat irritation, dizziness, and nausea. and a metallic taste. Welding smoke can also irritate the eyes, nose, chest, and respiratory tract and cause coughing, wheezing, shortness of breath, bronchitis, pulmonary edema (fluid in the lungs), and pneumonitis (inflammation of the lungs). Gastrointestinal effects, such as nausea, appetite loss, vomiting, cramps, and slow digestion, have also been associated with welding smoke. Some welding fume components and welding processes can be especially dangerous in a short period of time. Cadmium in welding fumes can be fatal in a short time.

Long-Term Health Impact:

Prolonged exposure to welding fumes may cause lung damage and various types of cancer, including lung, larynx, and urinary tract cancer. Ultraviolet radiation given off by welding reacts with oxygen and nitrogen in the air to form ozone and nitrogen oxides, which are deadly at high doses, irritate the nose and throat, and cause serious lung disease.

Health effects from certain fumes may include metal fume fever, stomach ulcers, kidney damage, and nervous system damage. Prolonged exposure to manganese fumes can cause Parkinson’s-like symptoms. According to the Workers Health Network, while there may be a genetic predisposition to developing Parkinson’s, most doctors believe that some environmental factor is involved, which triggers the disease. The development of this condition is especially associated with workers who have worked with manganese.

Gasses such as helium, argon, and carbon dioxide displace oxygen in the air and can lead to suffocation, particularly when welding in confined or enclosed spaces. Carbon monoxide gas can form, posing a serious choke hazard.

Workers in the area who experience these symptoms should leave the area immediately, seek fresh air, and obtain medical attention.

How is the productivity of workers lost due to welding fumes?

This pollution not only has a direct impact on the health of the workers and those working in the weld shop, but also on their working capacity and productivity. Due to pollution,

  • Workers are unable to concentrate completely on their work.
  • Excessive absenteeism due to illness (which costs the company as well as the worker)
  • Loss of concentration results in more mistakes, resulting in an increased amount of rework.
  • Taking more time to complete the work—overtime

Due to all this, both the worker and the company suffer huge losses, and pollution becomes the biggest hindrance to the progress of both. Is all this happening in your company/weld shop too?

A seemingly small thing in a factory environment, like welding fumes, can have ramifications ranging from your health to the company’s balance sheet and even future progress!

That is why controlling pollution is essential for a progressive welder and company.

Solutions to overcome welding fumes in industry:

Take into consideration controlling welding fumes in industry. First, get to know how much welding fumes are generated in your industry. Which type of welding is mostly used in your factory? How many workers work at a time? What is the time period for welding work?

So in industry, overcoming welding fumes is a major task, so various controlling measures should be taken. Some of the solutions to overcome welding fumes are:

General Ventilation Measures:

General ventilation uses roof vents, open doors and windows, roof fans, and floor fans to move air through the entire work area. These methods are not as effective as local exhaust ventilation and may actually spread chemicals around the workplace. However, general ventilation is often helpful when used to supplement local ventilation.

For example, if there is one small welding shop where 2–3 workers are working and there are 2 — 2.5 hours of welding work in a day, then using dilution ventilation we can reduce the pollution due to welding fumes. With the use of fans, we can maintain the level of distance between the welder and welding fumes. Another precaution we can take here is that welding work should be done near the wall on a table, and an exhaust fan should be installed to remove the fumes from the shop to protect workers from welding fumes.

Adopting the right welding procedure
Adopting the right welding procedure

Local Ventilation Measures:

Local exhaust ventilation systems can be used to remove fumes and gasses from the welder’s breathing zone. Keep fume hoods, fume extractor guns, and vacuum nozzles close to the plume source to remove the maximum amount of fumes and gasses. Portable or flexible exhaust systems can be positioned so that fumes and gases are drawn away from the worker. Keep exhaust ports away from other workers. Local exhaust can be provided by an extracting gun, which can reduce worker exposure to welding emissions by 70 percent.

LEV Representative Structure
LEV Representative Structure

For example, if there is a welding shop where 10–15 workers work and welding work is continuously done, such as in auto-component industries where LEV (local exhaust ventilation) needs to be used, and various types of suction hoods should be joined to the LEV to fetch fumes from welding stations and filter them to send them outside of the premises or inside.

Precautions While Welding
Precautions While Welding
Welding Fumes Solutions By Filter ON
Welding Fumes Solutions By Filter ON

There are various types of local exhaust ventilation.

Portable Fumes Extractor: When there is welding required for a big job that is handled by crane, we can’t use suction hoods there, so in that condition, the Portable Fumes Extractor plays a very important role in removing fumes from that area

In the Portable Fumes Extractor, there is a self-standing suction arm that the welder can adjust anywhere. To suck fumes from welding, the suction hood should be placed 100–300 mm near the welding work, as shown in Image A.

Welding Fumes Example
Welding Fumes Example

Fumes Extractor Image B, where a blower (fan) and a filter are used, which suck the fumes and filter them.

Stationary Type Fume Extractor: It is used for robotic welding stations or manual welding stations

A fume extractor system is installed on the top or side of the station. By placing a hood over the welding table or fixture, the fume extractor is connected to the hood through a pipe or duct. The welding fumes pass through the hood and pipe and enter the filter, where the smallest particles present in it are filtered, and the pure air goes out of the fume extractor through the fan.

Centralized Fumes Extraction System: When there are many (more than 15-20) weld stations in a weld shop, then installing a separate fume extractor for each weld station is not sufficient. Then centralized systems are used.

In a centralized system, all the weld stations are connected to a larger fume extraction system through ducting. This system can be installed inside or outside the shop. 

Total Clean Air Solutions By Filter ON (Centralized Systems)
Total Clean Air Solutions By Filter ON

Air quality monitoring:

Planning and maintaining a proper air quality monitoring schedule at scheduled intervals is the best option to reduce welding fumes and improve the overall workplace air quality. Monitoring the air quality helps industries choose the right equipment at the right time to overcome air pollution due to welding fumes. Filter-On also provides air quality testing services as per your convenience.

Scheduled Maintenance of Equipment:

Implementing a proper maintenance schedule for equipment is a task for every industry, as it ensures the performance of the machines and equipment and improves the overall air quality of the industrial environment. FilterOn’s after-sales service will be beneficial for you if you want hassle-free maintenance of welding fume extractors and other air quality improvement equipment.

Which type of system is best for your shop?

How many welding stations are there in your shop? How much welding is done? On which material is welding done? Does the shop layout remain fixed or change frequently? How is material handling done? By studying all these things, you can decide on the appropriate option.

After installing any type of system, it is important to understand and follow some things.

  • cleaning the filter in the system from time to time.
  • Checking blower/fan current and vibration
  • Checking the air flow of the system once a month

If there is a big shop in which more than 15-20 workers work together, then it is necessary to check the air quality before and after the installation of the system so that we get information about what effect the installation of the system has on the air quality. The objective is to provide a pure and safe environment for workers.

Govt. Regulations to overcome welding fumes in industry:

There are various government regulations created to overcome welding fumes and their hazardous impact on workers in industries. The criteria for safe air quality are specified in OSHA standards or the Factory Act. According to these, it is important to maintain air quality. Some of the well-known regulations are as follows:

Some OSHA standards applicable to welding are:

Why is safe air quality important?

  • The health of workers and other shop employees remains safe.
  • Their productivity remains at a high level.
  • Unproductive situations like absenteeism, rework, rejection, overtime, etc. lead to decline.
  • Higher productivity increases the profitability of the company.
  • Having a good, pollution-free environment in the factory helps the company get certifications like ISO 14000 and OSHA, and the brand image of the company is also good. This makes it easier for the company to attract new customers, retain good employees, and attract new employees. 
  • Safe air quality is one of the best investments for both the company and the worker.

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune, or mail us at : marketing@filter-on.com

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Clearing the Air: Understanding and improving Indoor Industrial Air Quality(IAQ)

Indoor Industrial Air Quality Blog
Indoor Industrial Air Quality Blog

Clearing the Air: Understanding and improving Indoor Industrial Air Quality(IAQ)

Many of us might have heard about indoor industrial air quality i.e. IAQ, many times in the news associated with air pollution. Unfortunately, the topic of air pollution gets reflected in the news more often these days because of increasing air pollution and more studies associated with its impact on human society.

In India, air pollution is the biggest killer. Some estimates show that 2.5 million premature deaths are associated with air pollution. Yes, 2.5 million in a year, which means 285 people per hour! Also, some studies show that air pollution costs India 8% of its GDP. huge economic cost.

It is because of this massive impact of air pollution on public health as well as on the economy that indoor industrial air quality becomes a very important parameter. Maintaining proper indoor air quality is of paramount importance to minimize the huge losses. Since the majority of our time is spent indoors (in homes, offices, factories, etc.), improving indoor industrial air quality (IAQ) is the only way to tackle this issue. Also, it is found in many studies that, contrary to our perception, indoor air quality is worse than outdoor air quality and thus affects more. This essentially means air quality in our homes, offices, and factories is worse than on the roads! Though unbelievable, many experiments and analyses show that it is a shocking fact.

What is Indoor Industrial Air Quality( IAQ)? Why is it a concerning factor nowadays?

The term often mentioned as industrial air quality, frequently reduced and mentioned with the abbreviation IAQ, fundamentally serves as an indicative metric or measure. It’s primarily used in numerous industrial sectors and scenarios to gauge, monitor, and assess the quality or general health of the air within a particular industrial environment or setting.

AQI, i.e., air quality index level, and IAQ are not similar. Air quality refers to outdoor air quality, which everyone breathes, but IAQ indoor or industrial air quality is experienced by employees in the industrial environment. The IAQ is more hazardous than the AQ because, in an industrial environment, different types of production are running on, so workers wearing without safety masks will have various health and breathing-related issues.

In industries, there are so many processes that generate air pollution, like welding, cutting, grinding, machining, heat treatment, etc. These processes generate very high levels of pollution, which makes indoor air quality inside industries extremely unhealthy and hazardous for the people working there. It also affects their productivity on account of a loss of concentration on the job, higher levels of fatigue, erratic absenteeism, and a loss of productive years of life. This indirectly affects the performance of such companies as overall productivity goes down and such companies lose competitiveness in the market. Just imagine if our nation as a whole has to bear 8% of its GDP as the economic cost of air pollution. How much would air pollution within an industry cost? Air pollution levels inside industries are much higher than our national average air pollution levels.

That’s why industrial IAQ has become an extremely important subject that no one in the industry can afford to ignore.

Indoor Industrial Air Quality(IAQ’s ) Impact:

Causes of poor Indoor Industrial Air Quality
  • Worker Health and Productivity: Poor IAQ can lead to respiratory issues, allergies, and other health problems among workers. Unhealthy employees are less productive, resulting in decreased efficiency and increased absenteeism.
  • Compliance and Regulations: Numerous governmental regulations and standards exist to ensure the well-being of industrial workers and the environment. Non-compliance can lead to fines, legal troubles, and damage to a company’s reputation.
  • Equipment Longevity: Dust and contaminants in the air can wreak havoc on machinery, leading to increased maintenance and repair costs along with production losses because of machine downtime. Ensuring cleaner air extends the life of equipment.

Solutions for Improvement of Indoor Industrial Air Quality( IAQ):

  • Effective ventilation: Invest in well-designed and maintained ventilation systems that can efficiently remove pollutants and maintain proper airflow.
  • Air Filtration:Employ advanced and appropriate air filtration systems, including high-efficiency particulate air (HEPA) filters, electrostatic precipitators, and carbon filters tailor-made for your industry’s needs.
  • Dust and Fume Control:Utilize dust and fume extraction systems to capture pollutants at the source, preventing their dispersion into the workplace.
  • Regular Maintenance:Consistently monitor and maintain all equipment, including HVAC systems, to ensure they function efficiently and effectively.
  • Environmental Management:Implementing environmentally friendly practices and sustainable production methods can improve the IAQ.

Filter-On has been working on this subject for the last 40 years, providing solutions for many applications to control industrial indoor air pollution and improve industrial IAQ. Over time, this has become our main vision. We found that there are huge gaps in the industry as regards awareness of the subject, understanding of technicalities, and attitude or approach to implementation, because of which many industries struggle to achieve desired results in this area in spite of spending significant money. Because of this, a lot of money is lost, and industries still keep losing because of the unresolved issue of poor industrial IAQ.

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune, or mail us at : marketing@filter-on.com

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Comprehensive Guide to Industrial Air Filtration & Fume Extraction Solution

Comprehensive Guide to Industrial Air Filtration & Fume Extraction Solution
Comprehensive Guide to Industrial Air Filtration & Fume Extraction Solution

Comprehensive Guide to Industrial Air Filtration & Fume Extraction Solution

Industrial air filtration and fume extraction for various industrial processes are hot topics nowadays in every industry. As fumes arise from welding, grinding, plasma cutting, laser marking, and other applications, these applications produce harmful fumes and mists, which will affect workers' health issues and productivity issues. Whether it is through an industrial welding fume extractor, an oil mist collector for CNC machines, or specialized pollution control equipment, clean air solutions are now essential for every factory. Here in this blog, we will discuss a comprehensive guide to industrial air filtration & fume extraction solutions by analyzing various applications, their fume exposures, health risks, and possible solutions.

Importance of Clean Air in the Industry:

  • Clean air is essential for health and safety.->Clean air through industrial air filtration and fume extraction systems is essential for health and safety. It helps protect workers from respiratory issues, allergies, and long-term health problems caused by pollutants. Solutions like solder fume extractors or kitchen exhaust scrubbers help reduce exposure in specific applications.
  • Improved air quality boosts productivity.-> Employees perform better in environments where they can breathe easily and feel comfortable. Installing specific solutions such as portable fume extractors for welding can directly improve the comfort and output.
  • It reduces health risks and absenteeism.-> Fewer illnesses mean lower healthcare costs and more consistent workforce availability.
  • Enhances the company’s reputation and goodwill.-> A commitment to clean air demonstrates corporate responsibility, improving public and collaborators’ trust. Adopting pollution control solutions helps to enhance a company’s reputation and goodwill.
  • Facilitates regulatory compliance.->Maintaining clean air helps industries meet occupational safety and environmental regulations more easily.

To obtain the aforementioned advantages, you must first examine the risks of welding fumes, as well as the reasons for implementing clean air solutions more quickly. Equipment like welding fume extractors or electrostatic precipitators helps industries meet safety and environmental standards. Effective pollution control devices in industries reduce harmful emissions and improve compliance with regulations.

Dangers of Industrial Fumes and Pollutants

In the modern world, neglecting industrial air filtration and fume extraction exposes workplaces to serious risks for anyone who  keep industrial environments’ air clean:

  • Health Risks at Workplaces
     Exposure to industrial fumes can lead to respiratory conditions and chronic illnesses, and without a welding fume extractor or proper fume extraction system, workers face bronchitis or even cancer and other long-term health complications. This has an adverse effect on the morale and well-being of employees.
  • Reduced Air Quality in the Workplace
    Pollutants degrade indoor air quality, making the work environment uncomfortable and potentially hazardous. This can result in breathing difficulties and decreased concentration among staff. A compact solution like a mobile welding fume extractor is designed to improve air quality in smaller work areas.
  • Damage to Equipment and Operations
     Industrial mists and fumes have the potential to contaminate or corrode machinery, resulting in unplanned production shutdowns, higher maintenance expenses, and more frequent breakdowns. An electrostatic oil mist collector prevents sticky mist buildup on CNC and grinding machines.
  • Decline in Workforce Productivity
     Health issues, absenteeism, and general discomfort among employees due to poor air quality contribute to reduced efficiency and lower output. A spot fume extractor placed near welding stations can significantly improve concentration and output.
  • Negative Impact on Reputation and Compliance                                                                                                                                                                  Poor air quality can harm a company’s reputation, signaling neglect of environmental responsibility and worker safety. It may also result in non-compliance with occupational health and environmental laws, resulting in fines or other consequences. Modern pollution control devices in industries not only prevent penalties but also project a strong image of responsibility.
Here we will quickly summarizes the main aspects above
AspectBenefits of Using Fume Extraction SystemsDangers of Not Using Fume Extraction Systems
Employee HealthReduces exposure to harmful pollutants, improving respiratory healthIncreased risk of chronic illness, respiratory problems, and allergic reactions
Air QualityMaintains clean indoor air for a safer and more comfortable workplacePoor air quality leads to discomfort, breathing issues, and reduced concentration
ProductivityHealthier employees are more productive and focusedSick workers and discomfort lower productivity and increase absenteeism
Equipment LongevityPrevents fume buildup on machinery, reducing wear and tearFumes can corrode equipment, cause malfunctions, and increase maintenance costs
Regulatory ComplianceHelps meet occupational health and environmental standardsMay result in violations, fines, or shutdowns for non-compliance
Company Reputation & GoodwillDemonstrates corporate responsibility and care for workers and environmentNegative public image due to unsafe working conditions

Overview of Industrial Pollution Control Technologies:

At Filter-ON, we combine advanced technologies to deliver industrial air filtration and fume extraction solutions, including ESP, cartridge, scrubbers, and centrifugal systems., Here is a summarized version of what we do.

Filter ON Technology
Filter ON Technology-ESP, Cartridge & Wet Scrubber
  1. Filter-ON ESP (Electrostatic Precipitator Technology): The electrostatic precipitation concept is the basis for how an electrostatic air filter operates. High voltage is used to ionize the small, submicron particles in the air, and the charged particles are then gathered on electrode plates with opposing polarities. An electrostatic force of attraction holds the particles that are deposited on the electrode plates in place. Clean, filtered air is expelled from the system in this manner, which separates the small, submicron-sized solid/liquid particles from the air stream.
    The principle of electrostatic precipitator working is widely applied in fume extraction, offering high efficiency at low operating costs. Industries evaluate both the electrostatic precipitator price and its long-term benefits, like zero filter replacement costs.
    With over 95% electrostatic precipitator efficiency, it is one of the most trusted technologies for fine particle filtration.

    Among the special benefits of electrostatic filters are

    • ·Cleanable and reusable filters have no replacement costs.
    • · The capacity to efficiently capture minuscule smoke, fume, and mist particles.
    • ·Extremely low pressure drops reduce fan power and, consequently, operating expenses.
  2. Bag/Cartridge Type Dust Collectors: Filter ON provides Bag/Cartridge Type Dust Collectors, which are efficient solutions for a variety of typical air pollution issues in industrial businesses. The equipment in this totally customized range is constructed in accordance with the site’s and the application’s exact needs. Systems with air flow capacity ranging from 1000 CMH to 60,000 CMH are available with different combinations of filtration area, filter media, static pressures, hopper configurations, etc.
    Operation: The cartridge filters draw in dusty air. On the outside of the filters, the dust layer accumulates. After a certain amount of time, a jet of compressed air is forced through the cartridge in the opposite direction. As a result, the dust that accumulates on the filter’s surface falls and gathers in the dustbin. Periodically, the dustbin has to be cleaned.  Here are the 

Advantages and Features 

  • We utilize German cartridges that have 99%+ filtration effectiveness down to 0.5 micron particles, making it feasible to filter fine dust. As a result, the air that is released from the outlet is safe, filtered, and clean for usage within the workplace.
  • The dust collecting pan only needed to be cleaned occasionally; automatic cleaning eliminated the need for ongoing maintenance.
  • Depending on the application, the cartridge life is 18–24 months

 Various sizes and configurations are available based on the demands of the application; a pressure gauge is supplied to indicate the condition of the cartridge filters.

 3. Centrifugal Coolant-Imperial Mist Collectors: When water-soluble coolants are employed, mist collectors work best in all typical machining activities, such as machining centers, lathes, grinding, etc. It is also widely used in the car component sector for collecting fumes and mist from component washing and cleaning equipment. These units are a common choice in machine shops because of their easy operation, small size, and inexpensive filter replacement costs. Based on air flow capacity, Filter On provides four distinct models, ranging from 400 Cu M/hr to 2,100 Cu M/hr. Modern CNC machining centers often require a reliable oil mist collector for CNC machines to protect operators and maintain clean air quality.
In addition to these kinds, if there is limited floor space, we also provide centralized fume extraction systems with shared ducting for several purposes.
By using modern pollution reduction technology, industries can improve air quality and worker safety while reducing costs.

Industry-Specific Solutions:

For the past 40+ years, Filter ON has been striving for “Mission Zero Pollution,” and we have more than 70 clean air solutions in industrial air filtration and fume extraction for  the following industrial applications:

  1. Welding Fume Extraction
  2. Oil Mist Collection
  3. Dust Collection
  4. Kitchen Dry Scrubber

Below is a summary of the sub-applications that are part of these industrial applications.

Welding Fume Extraction: Filter ON presents various solutions in welding fume extraction. Some of the important applications we cover up here are

  1. Robotic Welding Fume Extraction 
  2. Manual Welding Booths and SPMs
  3. Portable Welding Fume Extraction
Welding Fumes Solutions By Filter ON
Welding Fumes Solutions By Filter ON
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a) Robotic Welding Fume Extraction:

  • Provides robotic welding fume extractor solutions that are fume-free.
  • Includes welding SPMs, DID-type welding stations, and large robotic welding cells.
  • Efficiently extracts fumes from enclosed robotic areas, filters them using a high-efficiency electrostatic air filter, and returns clean air.
  • Provides four standard models and customizable options.
  • Systems include mounting stands, flexible pipes, semi-rigid aluminum pipes, flexible arms, and suction hoods.
  • Ideal for high-demand setups and automated weld fume extractor applications.
  • Installing an industrial welding fume extractor not only safeguards workers but also helps industries meet safety regulations.

“Read our full guide for this (coming soon).”

b) Manual Welding Booths & SPMs:

  • Designed for manual welding booths in various industries.
  • Mounted sideways or atop a weld cell, linked by flexible pipes or GI ducting.
  • Extract fumes from weld cell cabinets, filter through high-efficiency electrostatic air filters, and exhaust clean, safe air.
  • Provides four standard models and customized systems.
  • Suitable for medium amounts of dry fumes, small welding booths, welding SPMs, and DID-type welding stations.
  • Benefits include a high-efficiency electrostatic filter, zero replacement costs, and low running costs.
  • For larger setups, companies often rely on a welding smoke extractor with high-efficiency filters to remove hazardous particles.

“Read our full guide for this (coming soon).”

c) Portable Welding Fume Extraction:

Portable solutions like a mobile welding fume extractor are ideal for small workshops and electronics assembly lines. a drainpipe,

  • Essential tool for removing hazardous fumes during large crane-handled welding operations.
  • Features advanced electrostatic filtration technology with a pre-filter, after-filter, and ESP filter.
  • The suction head, positioned 200–300 mm from the fume source, captures and filters emissions.
  • Ideal for medium- to heavy-duty welding applications like earthmover bucket welding and propeller shaft welding in shipyards.
  • Compact and mobile, it requires zero filter replacement and adapts to changing operational needs.

“Read our full guide for this (coming soon).”

Oil Mist Collection Solutions By Filter ON
Oil Mist Collection Solutions By Filter ON
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  1. Oil Mist Collection:

Choosing the right oil mist filters ensures long-term efficiency and minimal maintenance in industrial environments, so Filter ON, one of the best oil mist collector manufacturers, presents oil mist collection solutions for the following applications:

a) Oil Mist Collector for 5-Axis Grinding

  • Designed for CNC grinding machines and tool & cutter grinders.
  • Employs proven mist eliminator filters and advanced ESP technology.
  • Utilizes electrostatic precipitators for efficient fume and mist extraction.
  • Includes flexible hoses, PVC rigid piping, a drainpipe, and a sturdy stand.
  • Supports oil recovery and provides a cleaner, safer environment for small machine shops.

“Read our full guide for this (coming soon).”

b) Oil Mist Collector for Gear Grinding/Hobbing Machines

  • Designed for grinding operations in various industries.
  • Engineered with mist collector filters and high-efficiency ESP technology.
  • Captures oil mist and fumes at the source, delivering excellent filtration performance.
  • Electrostatic precipitators ensure clean air through enhanced filtration.
  • Systems can be tailored to fit unique setups and include accessories.
  • Offers long-term value and cleaner work environments with washable components and almost zero replacement cost.

“Read our full guide for this (coming soon).”

c) Oil Mist Collector for Cold Forging (Nut Bolt Mfg. Machines)

  • Handles medium to high volumes of oil-based fumes in forging environments.
  • Powered by electrostatic precipitators for high-efficiency air purification.
  • Uses advanced mist eliminator filters to capture harmful particles.
  • Ensures cleaner air and a safer workspace.
  • Delivers reliable, compatible solutions like alternatives to LOSMA mist collectors.
  • Enhances worker safety and supports continuous, high-performance operations.

“Read our full guide for this (coming soon).”

d) Oil Mist Collector for VMCs and HMCs Coolant

  • Designed for VMC and HMC machines, ideal for machining operations.
  • Manages water-soluble coolant mist efficiently, ensuring cleaner, safer workspaces.
  • Uses centrifugal technology to condense fine mist into larger droplets.
  • Redirects recovered coolant back into the machine, improving operational efficiency and reducing fluid waste.
  • Offers advanced solutions based on ESP technology for capturing finer particulate and smoke from oil-based processes.

“Read our full guide for this (coming soon).”

e) Oil Mist Collector for Sliding Heads

  • Capture and remove harmful mist particles from sliding heads and CNC machines.
  • Mounted on stands or installed sideways, connected via PVC ducting or flexible pipes.
  • Extract oil mist directly from the machine and pass it through a high-efficiency electrostatic air filter.
  • Release clean, safe air back into the shop environment.
  • Core technology: Electrostatic precipitators for superior air filtration.
  • Features reliable ESP technology, washable mist collector filters, and low operating costs.

“Read our full guide for this (coming soon).

f) Oil Mist Collector for Sawing Machine

  • Specialized for sawing machines using oil-based coolants.
  • Protects workers from dangerous fumes and mists.
  • Handles medium to high mist volumes with efficient filters.
  • Leverages electrostatic precipitators for reliable, clean air delivery.
  • Ensures easy installation, low maintenance, and long-term cost savings.

“Read our full guide for this (coming soon).”

g) Oil Mist Collector for EDM Machines

  • Essential for EDM machine operations.
  • Capture and filter harmful fumes directly at the source.
  • Effective blower technology and superior ESP modulation were installed.
  • Foundational on the electrostatic static precipitator working principle.
  • Compact design for effortless shop floor mobility.
  • Integrated electrostatic mist collector filters offer 99.99% filtration efficiency.
  • Compatible with Filter Mist mist collectors, delivering clean air with zero replacement cost.
  • Combines high performance with low operating costs.

“Read our full guide for this (coming soon).

h) Oil Mist Collector for Pilger Mills

  • Precision-engineered oil mist collectors designed for high-speed metal forming.
  • Captures and filters mist at the source, ensuring cleaner air and healthier working conditions.
  • Utilizes mist eliminator filters and advanced ESP technology for safe, pollutant-free workplaces.
  • Provides efficient, low-maintenance solutions for continuous, high-volume production environments.
  • Washable and reusable systems suitable for tube rolling and cold reduction in Pilger mills.
  • Delivers reliable, energy-efficient filtration meeting industrial safety and air quality standards.

“Read our full guide for this (coming soon).”

i) Oil Mist Collector for Ballpoint Tip-Making Machines.

  • Precision-engineered for ballpoint tip-making machines.
  • Captures and filters mist at the source, protecting worker health and maintaining air quality.
  • Uses electrostatic precipitators to capture microscopic pollutants.
  • Advanced ESP technology and mist eliminator filters ensure high-efficiency filtration.
  • Delivers low-maintenance solutions with minimal running costs.
  • Ideal for continuous, high-volume production environments.

j) Induction Heating Application Solutions

  • Utilizes ESP for fume extraction in induction heating.
  • Cleans the air by capturing and filtering medium-to-large-level pollutants.
  • Increases worker health by lowering skin irritation and respiratory ailments.
  • Increases productivity by reducing downtime and employee morale.
  • Makes sure that industry standards and environmental laws are followed.
  • Saves costs by reducing maintenance and equipment downtime.
  • Principal advantages include no replacement costs, minimal operating expenses, compact design, and simple setup.

“Read our full guide for this (coming soon).”

k) Oil Quenching Application Fume Solutions

  • Provides industrial smoke and fume extractors to eliminate hazardous impurities from oil quenching.
  • Filters and absorbs medium-to-high concentrations of dry fumes, ensuring clean air for employees.
  • Benefits include improved health, increased productivity, and compliance with environmental regulations. • Provides industrial smoke and fume extractors to eliminate hazardous impurities from oil quenching.
  • Filters and absorbs medium-to-high concentrations of dry fumes, ensuring clean air for employees.
  • Benefits include improved health, increased productivity, compliance with environmental regulations, and cost savings.
  • Principal advantages include reliable electrostatic precipitator working, high efficiency, washable and reusable filters, lower operating costs, and dual benefits: safe environment and oil recovery. and cost savings.
  • Principal advantages include reliable electrostatic precipitator working, high efficiency, washable and reusable filters, lower operating costs, and dual benefits: safe environment and oil recovery.

“Read our full guide for this (coming soon).”

Dust Collection Solutions By Filter ON
Dust Collection Solutions By Filter ON
  1. Dust Collection Solutions:

Filter ON presents here different dust collection solutions in gauging, laser & plasma cutting, grinding, melting & furnace,, etc.

a) Dust Collector for Laser & Plasma Cutting Machines

  • Specially designed dust collectors and fume extractors for use in industrial settings.
  • Airflow capacities range from 1,000 CMH to 60,000 CMH.
  • High-performance German cartridge filters trap particles on the outer surface.
  • A compressed air jet dislodges accumulated dust, collected in a dustbin.
  • The self-cleaning mechanism maintains performance and extends cartridge life to 18-24 months.
  • Pressure gauges monitor filter condition in real time.
  • Ideal for grinding, welding, laser cutting, plasma cutting, and woodworking.
  • Offers 99%+ filtration efficiency, ensuring clean and safe air discharge.
  • Aligns with electrostatic precipitator working concepts for powerful filtration.

“Read our full guide for this (coming soon).”

b)Dust Collector for Grinding Machines

  • Provides pollution control solutions for grinding processes to maintain clean, safe work environments.
  • Includes industrial fume and smoke extractors to capture and filter grinding dust.
  • Features include high-efficiency filtration systems, compact designs, automatic cleaning mechanisms, and integration with industry pollution control devices.
  • Applications include metal grinding, tool sharpening stations, and precision grinding lines.
  • Leverages proven pollution reduction technology for environmental compliance and worker health protection.

“Read our full guide for this (coming soon).”

c) Dust Collector for Gauging 

  • Provides advanced solutions for dust-free gauging operations and worker health protection.
  • Features cartridge-type filters for superior air filtration.
  • Offers automatic reverse pulsed jet cleaning for minimal maintenance.
  • Includes add-on accessories like Spark Trap for enhanced safety.
  • Standard models range from 2000 CMH to 20,000 CMH.
  • Suitable for standalone workstations and manufacturing processes discharged by heavy fumes and dust.
  • Includes mounting stand, flexible pipes, GI ducting, and suction hood/canopies for targeted dust and fume extraction.

“Read our full guide for this (coming soon).”

d) Dust Collector for Melting & Furnace Operations

  • Engineered for melting and furnace operations to capture and filter fine dust and airborne particles.
  • Features high-efficiency filtration, compact, easy-to-install fume dust extractor designs, automatic cleaning, and compatibility with facility-wide pollution control systems.
  • Applications include melting and furnace operations and tool sharpening stations.
  • Solutions meet environmental standards, protect worker health, and reduce operational costs.

“Read our full guide for this (coming soon).”

e) Downdraft Table for Dust Collection

  • Designed for demanding applications like welding, grinding, woodworking, buffing, and plasma cutting.
  • Functions as an integrated workstation, capturing fumes, fine dust, and smoke at the source.
  • Suitable for manual operations, especially in grinding and buffing.
  • Available in three standard models with flexibility in size and airflow capacity.
  • Built on principles similar to electrostatic precipitators working for filtration enhancement without rotor protection, it improves indoor air quality and prevents particulate build-up.
  • Ideal for standalone stations with high-volume dust or fume discharge.

“Read our full guide for this (coming soon).

Enquire Now
Kitchen Dry Scrubber & Electrostatic Precipitator Solutions By Filter ON
Kitchen Dry Scrubber & Electrostatic Precipitator Solutions By Filter ON
  1. Electrostatic Dry Scrubbers for Industrial and Commercial Kitchens.

Restaurants and industrial kitchens benefit from a dry scrubber for kitchen exhaust that removes smoke, grease, and odors effectively. In heavy-duty industries, both wet and dry scrubbers are used to manage different types of pollutants.

  • Advanced air filtration solution for commercial kitchen exhaust systems.
  • Utilizes electrostatic precipitator principles to capture and filter out fine air pollutants and grease-laden particles.
  • Achieves 90–98% efficiency, removing particles as small as 0.01 microns.
  • Offers water savings, low pressure loss, and zero replacement costs.
  • Available in four models, it supports
  •  airflow capacities from 1200 CFM to 8000 CFM.
  • Compact design and reliable performance make it easy to install and operate in demanding environments.
  • Stands out among modern dry scrubbers for a cleaner, more sustainable cooking environment.
  • Our kitchen exhaust scrubber systems are compact, efficient, and built to meet environmental compliance.
  • Common electrostatic precipitator uses include welding fume extraction, kitchen exhaust cleaning, and oil mist collection.

“Read our full guide for this (coming soon).”

Enquire Now
Total Clean Air Solutions By Filter ON (Centralized Systems)
Total Clean Air Solutions By Filter ON
  1. Total Clean Air Project (Turnkey) Solutions
  • Offers turnkey solutions for customized clean air systems for various applications.
  • Addresses challenges in centralized or industrial welding fume extractor systems.
  • The process includes calculating airflow requirements, selecting appropriate filtration technology, developing feasible options, and assessing options using the Total Ownership Cost concept.
  • The consultative native process empowers clients to make informed choices and achieve true value for money.
  • Post-installation, comprehensive trials and testing are conducted to ensure technical parameters match initial design targets.
  • Training in system operation, maintenance, and troubleshooting is provided.
  • AMC services are offered for trouble-free maintenance throughout the system’s life.
  • Modification and retrofit projects for existing systems are undertaken.
  • Trusted clean air partner for the manufacturing sector, combining advanced welding smoke extractor technology with end-to-end project delivery.

“Read our full guide for this (coming soon).”

Enquire Now
Soldering & Laser Marking Fumes Extraction Solutions
Soldering & Laser Marking Fume Extraction Solutions
  1. Other Application Solutions.

Filter ON presents here some other application solutions, such as soldering application solutions, laser marking application solutions, and induction heating application solutions. These are discussed as follows:

a) Soldering Application Solutions

  • Ideal for maintaining air quality in the electronics, ICs, automation, automotive, and robotics industries.
  • Uses electrostatic or HEPA filters and efficient airflow technology to extract harmful soldering fumes.
  • Features versatile extraction setups like flexible pipes, semi-rigid aluminum ducts, adjustable arms, slotted benches, and top-mounted suction hoods.
  • Suitable for manual soldering stations and wave soldering applications.
  • Compact design and durable filter technology make it cost-effective.
  • Delivers reliable solutions with low running costs, minimal maintenance, and consistent performance.

“Read our full guide for this (coming soon).”

b) Laser Marking Machines Solutions

  • Specialized fume extraction systems for safe removal of hazardous fumes from laser marking processes.
  • Captures fumes at the source,rce, passes them through filtration, and releases purified air.
  • Available with electrostatic or HEPA filters, suitable for various industries.
  • Compatible with various ducting or pipe setups, offering versatility and easy integration.
  • Compact design, low energy consumption, and zero filter replacement cost for long-term operational savings

“Read our full guide for this (coming soon).”

So here Filter ON provides all these solutions to give an industry edge with its state-of-the-art electrostatic precipitation technology.

Enquire Now

FAQ for fume extraction systems comprehensive guide:

This comprehensive guide highlights why industrial air filtration and fume extraction are critical for worker health, productivity, and compliance across industries.

Q1: What is the best oil mist collector for CNC machines?

Ans: The Filter ON oil mist collector is one of the best oil mist collector solutions for CNC machines. Models like M02/2K DP are highly efficient at removing harmful oil mist, fumes, and smoke from machining centers. As one of the best oil mist collector manufacturers, Filter ON provides reliable industrial mist collectors, mist eliminator filters, and oil mist filters designed for high-performance CNC applications. Learn more on our website.

 Ans: An electrostatic precipitator works by charging fine dust, smoke, and oil mist particles using high-voltage electrodes. These charged particles are then attracted to oppositely charged collection plates, effectively removing contaminants from the air. This electrostatic precipitator working principle makes it highly effective for industrial smoke extractors, oil mist collectors, and kitchen exhaust scrubbers.

 Ans: Dry scrubbers use absorbent materials or sorbents to capture pollutants, while wet scrubbers spray liquids to wash contaminants out of the air. In industries like food, chemical, and manufacturing, both dry and wet scrubbers are widely used. A dry scrubber for kitchen exhaust is preferred where water handling is a challenge, while wet-dry scrubbers are used in heavy industries with high particulate matter.

Ans: Welding produces harmful fumes containing metals, gases, and particulates that can damage workers’ health. A welding fume extractor or industrial welding fume extractor prevents inhalation risks, improves workplace safety, and ensures compliance with industrial safety standards. Many welding fume extractor manufacturers also provide fume extractor accessories like fume extractor filters and fume extractor pipes for better performance.

Ans:Portable welding fume extractors, or mobile welding fume extractors, provide flexibility to capture fumes directly at the source, especially in confined spaces or field jobs. These portable smoke extractors with fume extractor filters act as mobile air-cleaning systems, ensuring clean air wherever welding takes place.

Ans: Kitchen exhaust scrubbers are essential in restaurants, hotels, food-processing plants, and industrial kitchens. A dry scrubber for kitchen exhaust or a scrubber for kitchen exhaust removes grease, smoke, and odors to maintain hygiene and meet local pollution norms.

 Ans: Common electrostatic precipitator uses include controlling air pollution in power plants, steel plants, cement factories, chemical industries, and commercial kitchens. Their ability to remove fine particulates, oil mist, and fumes makes them ideal pollution control equipment for multiple industries.

 Ans: The industrial fume extractor price depends on factors like capacity, filtration technology, and brand. Basic portable fume extractors are cost-effective, while high-capacity industrial fume extractors and Kemper welding fume extractors may cost more. Contacting leading fume extractor manufacturers ensures the best price-to-performance ratio.

Ans: The efficiency of an electrostatic precipitator can reach up to 99%, making it more effective than many conventional fume extractor filters. Unlike mechanical filters, ESPs require less frequent replacement, making them a cost-efficient choice in the long run.

Ans: Without an oil mist collector for CNC machines, operators are exposed to harmful aerosols that can cause respiratory issues and slippery floors. Contaminated air also damages sensitive machine components. Using a filtermist mist collector, oil mist filters, or electrostatic oil mist collector ensures both worker safety and longer machine life.

Ans: Yes. While Losma mist collectors and Kemper fume extractors are well-known, Filter ON offers customized fume & mist collectors with advanced industrial filtration equipment. Our products often outperform competitors in terms of durability, filter life, and maintenance cost.

Ans: Pollution control devices in industries, such as scrubber and electrostatic precipitator systems, fume smoke extractors, and dust & fume collectors, help reduce emissions and meet environmental regulations. These pollution control solutions also protect employees, improve workplace safety, and enhance corporate sustainability efforts.

To know more about fume extraction standards and regulations, please check here.

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Contact us at marketing@filter-on.com.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in industrial air filtration and fume extraction, including welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune and our virtual locations at Delhi, Bangalore, Ahmadabad, Hyderabad, or Chennai locations.

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Workplace Air Quality Monitoring: A Vital Tool for Enhancing Health and Productivity

Blog Banner-37- Workplace air quality monitoring
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Workplace Air Quality Monitoring: A Vital Tool for Enhancing Health and Productivity

Workplace air quality worsens day by day. In the previous blog, we discussed how important air quality mapping is for your workplace air quality improvement. In this blog, we are going to discuss how to measure air quality in the workplace and workplace air quality monitoring using a live case study example.

One of the world's most well-known vehicle chassis manufacturers is experiencing poor air quality at their welding section, so they contacted us to investigate the cause. We have planned a systematic approach to solve this particular case. We plan the following steps:

  1. We conducted an air quality mapping test to learn about fume exposure at the workplace.
  2. Based on the outcomes of the first test, we implemented the solutions in a phase-wise manner for each welding station.
  3. We conducted the second test after two months of implementation of solutions to test the effectiveness of fume extraction solutions.
  4. The analysis uses a live comparison to get precise conclusions.

Please check the below summary to understand the overall case.

Workplace Air Quality Monitoring

Summary of the case: How to measure air quality.

An internationally renowned auto chassis manufacturer has experienced problems with air quality at its Pune, Maharashtra, India, plant.

As a first step, the FILTER ON team decided to conduct air quality mapping of the work area.

Reasons for testing workplace air quality:

“To measure the actual workplace air quality and analyze the effectiveness of fume extraction solutions for plant site welding lines.”

Problems Faced By Client:

We conduct the workplace air quality mapping test because our client needs the following:

It helps to formulate targeted fume extraction strategies.

  1. They want a clear understanding of the status of the workplace air quality..
  2. They want to check the effectiveness of analyses after the implementation of solutions at their welding stations.
  3. They face fume exposure around the workplace due to the unavailability of fume extraction systems. .
  4. Workers face serious health concerns and productivity loss due to fume exposure at the workplace.

Actual Test & Results

We have carried out a workplace air quality mapping test in the six welding stations (W-3029, W-3012, W-3019, W-3047, W-3056, and W-3040). We tested the fumes' exposure to a variety of contaminants, including PM, CO, CO₂, SO₂, and O₂. The results were calculated throughout a 30-minute test period. The result was the outcome of a 30-minute test period. These results revealed that total particles were on the borderline at some locations when compared to permitted limits, while other measures, while still below permissible limits, were on the higher side, causing irritation and health risks for the operators.

Pre phase assessment

Fig. 1: Status of results before implementation of fume extraction systems

Solutions & Approach for Fume Extraction System Implementation:

After analyzing the workplace air quality data in Fig. 1 and the actual working conditions at the plant site, we designed a comprehensive strategy for minimizing fume exposure that utilized our best technology, electrostatic precipitation, to efficiently capture and filter the fumes. We implemented a solution with a fume extraction system with filtration units that included a canopy, hoods, ducting, filtration, and blower motor assembly as per suction parameters for each welding station.

This implementation provides clean air in the workplace, along with the following:

  • Lower pressure drop
  • Saves space on the shop floor
  • Duct lengths optimized

After the implementation of the system, we again conducted the air quality mapping at the same locations to compare the results. Following is the result after implementation:

Post implement phase results

Fig. 2: Status of stations after implementing solutions.

Results Achieved in Conducting Workplace Air Quality Mapping Test:

The following are the outcomes of the mapping test for workplace air quality: The following image shows a comparison of both test results.

Comparison of results from the pre and post stage test

Key takeaways from the workplace air quality mapping test:

The key takeaways from the results are as follows:

  • We assessed the pollutants such as CO, Cu, Fe, NO₂, SO₂, CO₂, welding fumes, zinc oxide, and Cr.
  • We measure each pollutant's permissible limits adhered to the Indian Factory Act.
  • There is a reduction percentage of 10% to 72% for the various pollutants after the implementation of the Fumes Extraction System. Welding fumes decreased by about 68% as compared to the previous state.
  • We found that there is the least reduction in sulfur dioxide and nitrogen dioxide, whereas copper fumes and zinc oxide show the highest reduction.
  • After implementing the solution, we can say that there was a significant reduction in fume exposure, and the workplace is now much safer and healthier than before, and thus more productive too!
  • Due to the air quality mapping exercise, it was easier to design optimum systems and also assess the performance of the system in very objective terms.
  • Also, this data was useful to the client for regulatory compliance required under EMS/OSHA/Factory Act, etc.

To know more about fume extraction standards and regulations, please check here.

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune and our virtual locations at Delhi, Bangalore, Ahmadabad, Hyderabad, or Chennai locations.

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