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Manual Welding Booth Fume Extraction: Choosing the Right Setup for Your Shop

Manual Welding Fume Extraction: Right Setup for Your Shop
Manual Welding Fume Extraction: Right Setup for Your Shop

Manual Welding Booth Fume Extraction: Choosing the Right Setup for Your Shop

Manual welding is an integral part of almost every manufacturing setup. Unlike robotic welding, which requires a higher investment and budget, manual welding is cost-effective and fits well within most operational budgets. That is why manual welding stations are present in nearly every manufacturing facility. However, an important question remains: what is the status of fume extraction at these manual welding stations?

Large organizations generally have the capability to install fume extraction systems for both manual and robotic welding stations unlike the small ones. In this article, we will cover Manual Welding Booth Fume Extraction in detail and discuss the right setup strategy for your welding shop.

Introduction to Manual Welding Fume Extraction

Manual welding includes various welding processes such as MIG welding, Stick welding, TIG welding, Plasma Arc welding, Electron Beam welding, and Laser welding. Each of these welding types generates fumes with different characteristics and therefore requires a suitable fume extraction system based on the welding process and several operational parameters. These parameters will be discussed one by one, starting with the potential dangers associated with manual welding.

Potential Dangers Due to Manual Welding

The risks associated with manual welding can be broadly categorized into immediate hazards and long-term health consequences, as outlined below.

Immediate Physical Dangers to workers:

  • Risk of getting electric shock: One of the most serious and immediate risks. Contact with live components, such as the electrode holder, can result in severe injury or fatal electrocution, especially in damp or wet conditions.
  • Skin burns: Welding temperatures can exceed 10,000°F, causing instant burns from arc contact, molten metal spatter, or hot workpieces.
  • Fire and Explosions: Sparks and hot spatter can travel up to 35 feet, easily igniting flammable materials, gas cylinders, or residues inside used containers such as drums.
  • Eye Injuries: “Arc eye” or welder’s flash is a painful corneal burn caused by ultraviolet radiation and can occur within seconds. Intense infrared radiation may also lead to immediate retinal damage.

Health Risks from Manual Welding Fumes

Manual welding produces a complex mixture of toxic metal particles and hazardous gases.

  • Respiratory Illness: Short-term exposure can cause metal fume fever, throat irritation, and breathing discomfort. Long-term exposure is linked to lung cancer, kidney cancer, and chronic obstructive pulmonary disease (COPD).
  • Neurological Damage: Inhalation of manganese fumes, commonly generated during mild steel welding, can cause irreversible nervous system damage and symptoms similar to Parkinson’s disease.
  • Suffocation: In confined spaces, shielding gases such as argon or helium can displace oxygen, leading to rapid unconsciousness or even death.

Long-Term Hazards

  • Radiation Exposure: Prolonged exposure to ultraviolet radiation increases the risk of skin cancer and ocular melanoma.
  • Hearing Loss: Noise from welding, grinding, and cutting operations often exceeds 85–100 decibels, which can result in permanent hearing damage over time.
  • Muscle or Joint Pains: Repetitive movements and sustained awkward postures can lead to chronic back, shoulder, and neck pain.

2025 Safety Standards

  • Mandatory Controls: Regulatory authorities such as HSE, CPCB, EPA, and OSHA state that welding operations should not be carried out without appropriate fume extraction or respiratory protection, regardless of job duration.
  • Strict Exposure Limits: As of 2025, several regions have reduced workplace exposure limits for welding fumes, including aluminum fumes, to improve worker safety.
Manual Welding Booth Fume Extraction: Choosing the Right Setup for Your Shop

Manual Welding Fume Extraction: What It Is and How It Works

The working principle of a manual welding fume extraction system involves capturing fumes directly at the source. A hood is installed above or beside the welding station and connected to the fume extractor through ducting. Welding fumes are drawn through the hood and ducts into the filtration unit, where fine particulate matter is captured. Clean air is then discharged through the extractor fan back into the workplace or outside, depending on the system design.

A properly engineered fume extraction system is essential to capture hazardous fumes directly at the source before they disperse into the work environment.
Equipment such as a fume collector, fume extractor, or fumes extractor plays a key role in improving workplace safety and ensuring compliance with occupational health standards.
For applications involving gaseous pollutants, a fume scrubber system is commonly used to neutralize harmful vapors before air is released or recirculated.

Welding fume extraction solutions for Manual Welding Booths:

Welding operations generate toxic metal fumes that require effective source capture. A dedicated fume extractor for welding or fume extractor welding setup helps control exposure in manual and automated welding stations.

A complete welding fume extraction system or welding exhaust system is designed based on welding type, enclosure conditions, and duty cycle.

Proper welding fume exhaust not only improves air quality but also supports regulatory compliance, while system selection from certified welding fume extractor manufacturers ensures reliability and long-term performance.

The welding fume extractor price typically depends on airflow capacity, filtration efficiency, and system configuration.

Factors to Consider for Manual Welding Fume Extraction

When selecting a manual welding fume extraction system, several important factors must be considered.

  • Number of Manual Welding Stations:  The number of manual welding stations plays a key role in determining the size and capacity of the fume extraction system. It directly impacts the total airflow requirement and the coverage area of the system.
  • Type of Welding & Manual  welding  fume extraction: Each welding process ARC, MIG, or TIG requires a fume extraction system designed according to its specific fume generation pattern and operational characteristics.
  • Size of Welding Fixture or Table (L × W × H):  The dimensions of the welding table or fixture are essential for calculating the required airflow capacity (CMH) of the fume extraction system.
  • Enclosure Details: The level of enclosure around the welding booth whether fully enclosed, partially enclosed, or open directly affects fume capture efficiency and exposure levels.
  • Material Handling System: The type of material handling system used, such as manual handling, automated systems, or EOT cranes, influences the placement and configuration of the fume extraction system.
  • Welding Cycle Time:; The actual duration of welding operations determines overall fume exposure and helps define the required extraction capacity.
  • Layout Availability: If a detailed layout is available, it becomes easier to plan optimal placement of the fume extractor and ducting. Proper layout planning ensures effective fume control without obstructing worker movement or compromising safety.
Frequently Asked Questions (FAQs)

Is fume extraction mandatory for manual welding?
 Yes. Safety authorities such as OSHA, HSE, CPCB, and EPA mandate the use of appropriate fume extraction or respiratory controls during manual welding to reduce exposure to hazardous fumes and protect worker health.

Which fume extraction system is best for manual welding booths?
 The ideal system depends on factors such as the welding process, number of welding stations, enclosure design, and airflow requirements. Common solutions include extraction arms, welding hoods, and downdraft tables that capture fumes directly at the source.

Are welding fumes harmful during short welding operations?
 Yes. Even short-term exposure can cause metal fume fever, respiratory irritation, and eye discomfort. Repeated exposure without proper fume control can result in serious long-term health issues.

Can one fume extractor serve multiple manual welding stations?

Yes. A centralized fume extraction system can serve multiple manual welding stations if it is properly designed with adequate airflow capacity, balanced ducting, and effective fume capture at each station.

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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Volatile Organic Compounds (VOCs): Health, Safety & Solutions

Volatile Organic Compounds (VOCs): Health, Safety & Solutions
Volatile Organic Compounds (VOCs): Health, Safety & Solutions

Clearing the Air: Understanding Volatile Organic Compounds (VOCs) – Examining Pollution, Health Impacts, Safety Limits, and Industrial Solutions for Risk Mitigation

When we think about pollution, we have thoughts about its various sources and main pollutants, such as transportation, industrial pollution, CO2, SO2, and volatile organic compounds (VOCs). VOCs are small organic compounds that are present in the air and play a vital part in air pollution. We are here to discuss the VOC, its impact on health, safety limits, and solutions to restrict the risks associated with VOCs.

What are VOCs?

Volatile organic compounds (VOCs) are a group of chemicals that highly vaporize into the air. Chemicals like benzene, ethylene glycol, methylene chloride, tetrachloroethylene, toluene, xylene, and 1,3-butadiene. These VOCs are themselves harmful, and some of them combine and form other pollutants as well.

Common products where VOCs are mostly present:

  • Paints, paint strippers, and other solvents
  • Wood preservatives
  • Aerosol sprays
  • Cleansers and disinfectants
  • Moth repellents and air fresheners
  • Stored fuels and automotive products
  • Hobby supplies
  • Dry-cleaned clothing

VOCs as pollutants:

Volatile organic compounds (VOCs) are a group of pollutants that are responsible for air pollution. Some of the sources of VOCs are as follows:

Volatile Organic Compounds (VOCs): Health, Safety & Solutions

Natural Sources-

Volatile organic compounds Natural sources are as follows:

  • Plants: Many plants release harmful chemicals, and some can even absorb them.
  • Forest fires: Natural forest fires are a source of VOCs.
  • Anaerobic moors: Anaerobic moors processes are a source of VOCs.
  • Cattle farms: Cow manure is a volatile source of methane, a potent greenhouse gas.
  • Anything burning: Anything that burns can be a source of VOCs.

Some of the other natural sources include volcanoes and fermentations.

Artificial Sources-

Artificial, man Made sources of VOCs include fuel production, distribution, and combustion, with the largest source being emissions from motor vehicles due to either evaporation or incomplete combustion of fuel and from biomass burning.

Volatile organic compounds (VOCs) are industrial solvents, fuel oxygenates, and by-products from water treatment. They are often found in petroleum fuels, hydraulic fluids, paint thinners, and dry cleaning agents.

VOCs can come from industrial sources such as:

  • Burning fossil fuels
  • Power generation
  • Manufacturing chemicals
  • Crude oil processing
  • Some metal production processes

Other sources of VOCs include:

  • Gasoline, fuels, and solvents
  • Paints, stains, strippers, and finishes
  • Pesticides
  • Personal care products
  • Aerosol sprays
  • Cleaners and room deodorizers
  • New cabinets, furniture, and beds
  • New carpets, rugs, and wood floors

According to Energy Education, a major contributor to VOCs is the evaporation of hydrocarbon-rich liquids. These include:

  • Gasoline from car tanks or refueling stations
  • Industrial solvents such as oil-based paint
  • Barbecue starter fluid
  • Cleaning products

Health Effects of Volatile Organic Compounds (VOCs)

The health effects of VOCs are as follows:

The health effects of VOCs on industrial workers and general people are categorized by short-term exposure and long-term exposure limits. Short-term exposure effects on health are immediate, and they have been for short periods of time, may be a few hours or a few days, whereas long-term health effects can be long-term exposure, may be a few years, to permanent effects on health. Both are categorized as under.

Short-term:
Short-term exposure to various VOCs may cause:

  • Irritation of the eyes and respiratory tract
  • Headaches
  • Dizziness
  • Visual disorders
  • Memory problems

Long-term:
Long-term exposure to various VOCs may cause:

  • Irritation of the eyes, nose, and throat
  • Nausea
  • Fatigue
  • Loss of coordination
  • Dizziness
  • Damage to the liver, kidneys, and central nervous system
  • Cancer

Industrial Safety Limits for VOCs

Safety Guidelines for Industries by CPCB With respect to VOC exposure

The industries can look more closely at the following aspects for the control of VOCs:

  • Closed handling system for chemicals.
  • Improved solvent recovery through the use of some special condensers and subcooling systems.
  • Mechanical seal for chemical handling pumps.
  • LDAR system – Venting of storages with trap receiver and condenser.
  • Training for the laborers and staff.
  • Proper system of loading and unloading of solvents.
  • Proper solvent recovery systems.
  • Work environment monitoring with respect to VOC has to be conducted and compared with the Factories Act’s occupational health standards.
  • All the emissions emitting sources are to be channeled through ducts to a common conduit, and after advanced condensers and/or scrubbing with relevant or proper scrubbing, the treated emissions are to be let into the air.

Solutions for VOC exposure in industrial environments:

Solutions for VOC exposure in industries are as follows:

Proper Ventilation Measures:

Proper ventilation measures, such as LEV (local exhaust ventilation), must be installed in high-exposure areas of industries for worker safety.

Use of Extraction Systems:

Using extraction systems like Filter On India’s Clean Air Solutions in welding fumes solutions, oil mist extraction and dust collection solutions like welding fumes extractors, oil mist collectors, dust collectors, downdraft tables, and ESP filtration systems with HEPA must be used to control VOC exposure in industrial environments.

Follow guidelines set by authorities.

With regards to worker safety, industries must follow guidelines set by different authorities, such as OSHA, EPA, and CPCB, to control VOC exposure in industries.

Industrial safety limits for VOCs are provided by OSHA,EPA, ACGIH, and in the Indian context, CPCB.

As per OSHA, ACGIH, and NIOSH, the permissible exposure limits for VOCs are as follows-

Exposure Limits
OSHA (PEL)for general industry: 50 ppm (240 mg/m3) TWA; Skin for the Construction Industry: 50 ppm (240 mg/m2) TWA; Skin for Maritime: 50 ppm (240 mg/m2) TWA; Skin
ACGIH (TLV)20 ppm; Appendix A3: Confirmed Animal Carcinogens with Unknown Relevance to Humans
NIOSH (REL)5 ppm (24 mg/m2) TWA
NIOSH (IDHL)700 ppm

The OSHA standards for VOCs can be read here.

Another example of regulations relating to VOC safety includes the EPA’s regulation 40 CFR 59. This federal regulation, “National Volatile Organic Compound Emission Standards for Consumer and Commercial Products,” targets overseas manufacturers and importers of certain products and seeks to ensure that such parties remain in compliance with VOC emission standards.

In the Indian context, the CPCB (Central Pollution Control Board) has set the permissible exposure limits for pollutants, so for VOCs, its limits are as follows:

Moreover, there is no legislation for VOC in ambient air in India. As per the National Ambient Air Quality Standard (NAAQS) of India, benzene is the only VOC whose standard has been prescribed as 5 μg/m3 since November 2009.

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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Understanding Sulphur Dioxide(SO2):Sources Of Pollution, Health Impact, Knowing Safety Limits and Solutions

Sulphur Dioxide(SO2) Blog Banner Image
Sulphur Dioxide(SO2) Blog Banner Image

Understanding Sulphur Dioxide(SO2):Sources Of Pollution, Health Impact, Knowing Safety Limits and Solutions.

Sulphur Dioxide (SO2) is one of the most significant primary air pollutants after carbon dioxide and nitrogen oxides. This harmful gas plays a major role in industrial air pollution and poses serious risks to workers’ health and workplace safety. In this article, we explore how SO2 becomes a threat in industrial environments, its health impact on workers, the safety limits required to control SO2 exposure, and the key government regulations designed to reduce the risks associated with Sulphur Dioxide in industries.

What is sulfur dioxide(SO2)?

Sulfur dioxide (SO2) is a colorless, toxic gas with a strong, choking odor. It's a member of the sulfur oxide (SOX) family of chemicals, which are made up of sulfur and oxygen.

Sulfur Dioxide (SO2) as a Pollutant

Sulfur dioxide has various sources of pollution; some of the sources are as follows:

Natural Sources

Sulfur dioxide is naturally generated through

Volcanic Eruptions

Artificial Sources

There are two types of artificial sources of SO2.

  • Industrial Sources
  • Other Sources

In industries, SO2 is generated through petroleum refineries, cement manufacturing, paper pulp manufacturing, and metal smelting and processing facilities.

Other sources of SO2 include locomotives, large ships, and some non-road diesel equipment that currently burns high-sulfur fuel and releases sulfur dioxide into the air.

Burning fossil fuels (coal and oil) for domestic heating is also a source of SO2

Highest Concentration Of SO2 In The World –

In the world scenario the highest concentration of SO2 is from our country India, then on the second spot is Russia and Third is China.:

India as the largest emitter of SO2 in the world, contributing more than 21% of global emissions mainly coming from coal-based electricity generation.

Sulphur dioxide(SO2) sources and health impact

How are you exposed to Sulphur dioxide(SO2)?

You can be exposed to Sulphur dioxide(SO2) by breathing it in the air or getting it on your skin. People who live near industrial sources of sulfur dioxide may be exposed to it in the air. You are most likely to be exposed if you work in industries where SO2 is produced, such as copper smelting or power plants, or where it is used in the production of sulfuric acid, paper, food preservatives, or fertilizers. People with malfunctioning appliances or chimneys in their homes may also be exposed to sulfur dioxide.

Most SO2 exposures are caused by people breathing contaminated outdoor air.

SO2 Impact on Health:

The impact of SO2 on health consists of short-term and long-term impacts.

Short-Term Impact of SO2 on Health:
Exposure from breathing sulfur dioxide can cause:

  • Burning of the nose, throat, and lungs
  • Difficulty breathing
  • Loss of smell
  • Headaches and dizziness
  • Nausea and vomiting
  • Harm to the respiratory system: As an irritant, sulfur dioxide can affect lung function and cause and worsen respiratory diseases in humans and animals.

Exposure to very high levels of sulfur dioxide can be life-threatening.

Touching liquid sulfur dioxide can cause:

  • Frostbite
  • Irritation of the eyes:

Long-Term Impact of SO2 on Health:
Long-term exposure to sulfur dioxide can cause:

  • Changes in lung function

SO2 emissions that lead to high concentrations of SO2 in the air generally also lead to the formation of other sulfur oxides (SOx). SOx can react with other compounds in the atmosphere to form small particles. These particles contribute to particulate matter (PM) pollution. Small particles may penetrate deeply into the lungs, and in sufficient quantity, they can contribute to health problems.

  • Bronchitis and shortness of breath

People with asthma may be sensitive to changes in respiratory effects due to SO2 exposure at even low concentrations. Sulfur dioxide is not classified as a human carcinogen (it has not been shown to cause cancer in humans).

  • Decreased fertility in women and men:

 Continuous inhalation of SO2 affects fertility rates in women and men.

Solutions for SO2 Exposure at Industries

Safety measures taken by industries Include the following:

Use ventilation systems.

Use of ventilation systems like LEV (local exhaust ventilation) can reduce the exposure to SO2 to some extent, which leads to an increase in air flow capacity in the work environment, which is very important for workers health.

Use of Extraction Systems:

Using extraction systems for air pollution control is the best solution to protect workers from high exposure to SO2-like pollutants, such as  Filter On  welding fume extraction systems, oil mist collectors, and dust collection systems will be very beneficial for industries to reduce the risk of SO2-like pollutants on workers health.

Use the government guidelines.

Using and following the government guidelines from time to time will surely reduce the exposure of SO2 in industries, and it will have a positive impact on society.

Here are some safety precautions for SO2 exposure, including:

  • Using personal protective equipment as required
  • Increasing ventilation in the area or moving a leaking container to a well-ventilated and secure area
  • Stopping or reducing the leak if it is safe to do so
  • Knocking down gas with fog or a fine water spray

Safety limits for SO2 exposure.

As per OSHA, the permissible safety limits for SO2 exposure are as follows:

SO2 OSHA Limits

In India, as per CPCB-Central Pollution Control Board Of Regulation the SO2 Exposure limits are as follows-

CPCB SO2 Exposure Limits

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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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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Fume Extraction Standards & Regulations: The Essential Guide to Safer Workspaces and Smarter Investments

Fume Extraction standards and regulations
Fume extraction standards and regulations

Fume Extraction Standards & Regulations: The Essential Guide to Safer Workspaces and Smarter Investments

Global market changes Day by day, manufacturers and companies need to comply with standards and regulations at every manufacturing process, such as welding, brazing, oil mist, dust collection, laser marking, laser cutting, etc. These processes need to comply with the safety standards and government regulations for each process as per the latest government norms specified.

Fume extraction standards and regulations

Safety Standards and Exposure Limits For Workers—Welding Applications:

As per the OSHA factsheet and India's PEL (Permissible Exposure Limits), the welding process is as follows:

OSHA standards for galvanized steel:

OSHA warns of welding hazards in galvanized steel and stainless steel. Galvanized steel, coated with zinc, can cause metal fume fever.

Want to know about health hazards related to welding fumes? Click here to read more.

OSHA standards for stainless steel:

Stainless steel coated with chromium is highly toxic and can cause cancer. Companies have a duty to guarantee that no worker is exposed to levels of chromium greater than 5 µg/m³.

Safety Standards and Exposure Limit for Workers: Oil Mist Applications:

The OSHA Occupational Safety and Health Administration sets permissible exposure limits for air contaminants in metalworking fluids, including oil and solvent mist. These limits are set at 5 milligrams per cubic meter for an 8-hour, time-weighted average (TWA).

The Indian government's Factory Act also follows these standards to control oil and coolant mist exposures in India. Vent lines at lubrication points are also required to collect stray mist.

Want to know about health hazards related to oil mist? Click here to read more.

Safety Standards and Exposure Limit for Workers: Dust Exposure :

As Per OSHA and Indian Factory Act:

Typically, the PEL for total dust is 15 mg/m3, while respirable particles have a lower PEL of 5 mg/m3.

Safety Standards and Exposure Limit for Workers: Laser Marking Applications:

  • The Occupational Safety and Health Administration (OSHA) has established safety limits for laser marking, categorized into different classes based on their power and potential hazards.
  • Class 1 is safe under all conditions, while Class 2 is safe for short viewing times but can cause eye damage if mishandled.
  • Class 3B is unsafe for direct viewing and can cause skin and eye injuries.
  • Class 4 is high-power lasers that can cause skin and eye injuries and fire hazards.
  • Laser beams should not be directed at employees, and systems should not be operated in rainy, snowy, or dusty weather conditions.
  • Other safety limits include limiting diffused reflected light to 2.5 watts per square centimeter, preventing employees from exposure to microwave power densities above 10 milliwatts per square centimeter, and having removable panels and doors with interlocks that automatically reduce or stop laser emissions when the enclosure is opened.

Safety Standards and Exposure Limit for Workers: Laser Cutting Applications:

  • The Occupational Safety and Health Administration (OSHA) has established safety limits for laser equipment, categorized by power and hazard level.
  • Class III B lasers are moderate power, while Class IV high power lasers pose hazards to view, ignite materials, and produce air pollutants.
  • It is not appropriate to point the laser beam toward workers, and it is not advisable to run systems in wet, snowy, or dusty environments.Laser equipment labeling should indicate its maximum output, and Class IIIB or Class IV lasers should be enclosed in a Class I enclosure or have a Laser Safety Officer present.
  • Ideally, the laser unit should be set up above employees' heads.

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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