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

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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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Air Quality Mapping: Your First Step to a Healthier Workplace

Workplace Air Quality
Workplace air quality

Air Quality Mapping: Your First Step to a Healthier Workplace

Workplace air quality is a serious issue nowadays. In the industrial environment, the workers face several health issues due to poor air quality. So air quality mapping is an important task for every industry nowadays. It provides various benefits to industries, but the most important benefit is “to plan a strategy to control the fumes in the workplace." Air quality mapping is the first step of every industry towards a healthier workplace.

What is air quality mapping?

The following are a few important things that will tell you what air quality mapping is all about.
  • To assess each workstation's actual air quality in order to ascertain the air quality condition of the workplace.
  • Take the readings in Mg/M3 format for each workstation in the workplace.
  • Carefully analyze and study the readings to understand the actual exposure level of each workstation in the workplace.
  • After complete analysis and study, prepare a foolproof air quality map in accordance with the workstation layout in the workplace to make the workplace healthier.

Workplace Air Quality

Why is air quality mapping important?

Air quality mapping is important for the following reasons:

To locate real hotspots for occupational fume exposure.

Air quality maps, in addition to visually displaying areas with high pollution levels, can identify areas where the actual level of fume exposure is critically high in the workplace or assist in identifying a single workstation area where fume exposure is high.

It helps in taking corrective decision-making.

A proper air quality map can help in taking corrective decision-making, and it can help allocate the required funds to implement a fume extraction system and solution. It helps with health risk assessment in the workplace.

Air quality mapping will help in understanding the extent of health risks to the workers due to poor workplace air quality.

It helps to formulate targeted fume extraction strategies.

Air quality mapping helps to formulate the targeted fume extraction strategies for those hotspots where the amount of fume exposure is very high. One can easily target the areas with the help of an air quality map.For example, generally, 20% of the workstations in the layout will be responsible for generating 80% of the pollution. AQ Map helps the planner identify those 20% of workstations for ‘targeted action.’

How is the air quality mapping test conducted?

A Filter ON representative comes to your plant and performs the test in the manner described below.

  • He uses a digital aerosol monitor to measure dust concentration at the operator level.
  • He categorizes results into Red Zones (pollution above safe values), Yellow Zones (pollution on the borderline of safe values), and Green Zones (pollution within safe values) on the plant layout.
  • Then Filter ON provides a report with recommendations for lowering exposure levels in red and yellow zones after analyzing the processes.
  • It enables planning for corrective actions like improved ventilation, enclosures, and pollution control devices.

Filter ON helps you to formulate the required air quality mapping test with its fume extraction systems because Filter ON has 40+ years of experience to develop and implement fume extraction systems for various industrial processes such as welding, oil mist, dust collection, laser marking, laser welding, and in commercial kitchen dry scrubbers. With this wide range of experience and 70+ different solutions to cater to the needs of industrial air pollution market, Filter ON wants to become your trusted partner for all the above offerings, so for your fume extraction needs, contact us at marketing@filter-on.com.

To make a corrective decision and plan the methods for implementing air quality mapping with fume extraction systems in your industry, please see our previous blog series, "Designing a Complete Clean Air System: A Guide to Effective Planning", as well as other blogs following this one.

In the next blog post, we will discuss the necessary steps that need to be carried out to perform air quality mapping in your workplace with a case study and also check the effectiveness of air quality mapping at your workplace.

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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5 Key Ways: To Improve performance of your Fume Extraction Systems

Improve the fume extraction performance with 5 essential tips
Improve the fume extraction performance with 5 essential tips

5 Key Ways: To Improve performance of your Fume Extraction Systems

Fume extraction systems are crucial pieces of equipment for any industry that uses metalworking, such as those that perform welding, machining, heat treatment, laser cutting, plasma cutting, EDM, and grinding processes. In this blog post, we go over the 5 key ways to make your fume extraction system work better so that you can know how you can improve the fume extraction system’s performance.

Enhancing your fume extraction system's functionality is crucial for the following reasons:

The following are benefits of performing fume extraction systems in your factory:
  • The air in your factory will remain clean and healthy.
  • Protection of Employee Health
  • Improvement in overall productivity on the shop floor
  • An improvement in the company's goodwill

Many progressive organizations make large investments in establishing fume extraction systems because of these advantages. However, it is discovered that the manufacturing environment is still contaminated in numerous locations despite the presence of fume extraction equipment.

But—hold on?

If, despite owning a fume extraction system, you do not experience the aforementioned advantages, you should reconsider and look into the following problems to determine the true cause. Filter ON is eager to assist you and offer answers when required. The primary cause is these systems' less-than-ideal performance. The following are some of the most frequent problems encountered:

5 Key Issues That Are Deteriorating the Performance of the Fume Extraction System:

If your mist collector is based on ESP technology, then you need to follow these maintenance tips:

Inadequate fume capture:

This may be the result of
  • Inadequate airflow capacity of fume extractors
  • Improper hood/enclosure design
  • Change in manufacturing process/cycle time, etc.
  • Choked filters due to which equipment cannot produce the required airflow

Not enough filtration efficiency

Different types of air filters have different capabilities. Thus, it is needed to select the right filtration method for the right application. If the filtration process is not suitable for the process, it will not be able to treat the fumes and filter them to safe levels. And thus, in spite of having a system, still the problem of fumes is not getting addressed.

Another factor is the neglect of filter maintenance.If the filters are old and ruptured and not replaced in time, the fumes will bypass such filters and escape in the shop environment. In the case of electrostatic filters, if the maintenance is not done after filters are choked and tripped, it will not filter the fumes efficiently. So, even if you are using the right kind of filters for the right kind of application, periodic maintenance is extremely important.

Frequently occurring breakdown:

Frequent breakdowns of fume extraction systems are due to overload of filters or overload of electric motors. Overload in filters may take place due to improper cleaning of filters, not maintaining the preventive maintenance schedules, or incorrect filter selection.

Frequent overload of the motor takes place due to improper blower-motor selection, faulty overload setting, or filter choke.

Due to frequent breakdowns in fume extractors, it is not able to extract and filter the fumes consistently, which leads to fumes escaping the shop and resulting in a polluted work environment.

Costly spare parts:

Many times, imported machine tools come fitted with fume extractors and mist collectors. However, the spares of such imported fume extractors are found to be extremely costly with long lead times. Thus, the replacement is delayed by management, causing suboptimal performance or breakdowns of such imported fume extractors.

Certain components of the fume extraction system must be changed periodically. For example, if your system has cartridge filtration, you should replace it when it starts to get dirty and exhibit issues with fume capture.

Issues with support and service:

One of the challenges, especially with imported fume extractors as well as some domestic manufacturers, is that the after-sale service for the equipment is not available, due to which such equipment remains in breakdown or has to be scrapped before the useful life is over.

For the fume extraction system to operate at its peak efficiency, these problems must be resolved.

So how can FilterON help you to solve the problems mentioned above?

For the past 40+ years, Filter ON India has been striving for "mission zero pollution" in the Indian air filtration industry. Filter ON, an industry partner for clean air solutions, has created and implemented 70+ clean air solutions for various applications in the industry, such as welding, brazing, grinding, plasma and laser cutting, and CNC machining.

So Filter ON has the expertise to solve the above issues and provides you the solutions to get your fume extraction problem solved. So some of the solutions we provide here are the top 5 solutions that you can think to implement:

5 Key Ways to Improve Performance of Your Fume Extraction Systems:

Improve the fume extraction performance with 5 essential tips

Machine Health Check:

By using its experience, Filter ON offers comprehensive machine health checks and can identify filtration-related problems in the work environment. Our sales or service staff will visit your location and will check some key parameters like air flow capacity, rated motor currents, and high voltage measurement (in the case of electrostatic systems) to provide you with comprehensive information about the state of the work area. With this information, proper corrective action can be planned to revive the non-performing systems which ultimately improve the fume extraction system’s performance.

Modifications:

Due to process changes, layout changes, etc., many times it is required to make relevant changes in the fume extractor system and its ducting/hood arrangement to make it effective. FilterON’s experienced design team can help in this task to ensure maximum utilization of your existing systems, which would save significant costs for you.

Renovating

There are some very old fume extractor systems with clients that would need major reconstruction. The FilterON team carefully analyzes and protects the costly spares & components in such systems and renovates the complete system to function as well as a brand new system at much lower cost than buying a new system. With this service, the FilterON team literally gives a new life to an old, outdated system, saving huge resources.

New Installations:

We provide the installation of modern fume extraction systems. Our ISO 9001:2015 and CE-marked full fume extraction solutions can undoubtedly address most of your fume extraction problems to ensure a clean and productive work environment at the lowest total ownership cost.

Imported machine component substitutes:

Filter ON offers alternative, localized spares for imported machines, eliminating worry about spare parts and improving efficiency, ensuring the safety and performance of your fume extraction system.

So by applying these measures we can conclude that we can improve fume extraction system’s performance to an greater extent.

Please contact us if you have any questions about fume extraction performance improvement.
Email us: marketing@filter-on.com

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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Oil Mist Collector Maintenance: Filter ON’s Expert Tips for Optimal Performance

Oil mist collector maintenance
Oil Mist Collector Maintenance

Oil Mist Collector Maintenance: FilterON’s Expert Tips for Optimal Performance

In filtration industries, oil mist collectors play a vital role in collecting mist particles generated during the machining process, but do you know how to maintain an oil mist collector for optimal performance? What are the maintenance guidelines, i.e., tips to follow? We will see in today’s blogpost how one can clean and maintain an oil mist collector for optimal performance with Filter ON’s Maintenance Tips Guide.

Why do oil mist collectors need maintenance?

Proper maintenance of mist collectors is crucial for preventing safety hazards in the work environment. These devices capture harmful particles, preventing them from entering the workplace. Inadequate maintenance can lead to filter clogging and equipment failure, posing safety risks as well as the risk of costly component failures in the mist collectors. Regular maintenance of the oil mist collector ensures its optimal performance, which prevents escalating issues at the time of use and ensures workplace safety for workers.

Technology Wise: Oil Mist Collector Maintenance Tips

Every oil mist collector has different types of technology used, such as ESP (electrostatic precipitator) and mechanical/centrifugal mist collectors.

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

Electrostatic Precipitator Technology:

If your mist collector is based on ESP technology, then you need to follow these maintenance tips:

Cleaning Procedure:

There are different ways to clean the ESP filters, such as by wiping the surface of the filter or using compressed air to clean the filters. The most convenient and effective way is to use Filter ON’s F1 cleaning powder solution.

Procedure of F1 Cleaning Powder Solution:

For mixing the FilterON FN-1 cleaning powder, you require a large-sized water tank, and the shape must be round or square. i.e.

The proportion of chemical and water is to mix the chemical in 70-80 liters of water with 1 kg of F1 cleaning powder.

  1. Stir uniformly for 5 to 10 minutes to form a homogeneous solution.
  2. Dip or soak the ESP Cell (Stack) for 25 to 30 minutes in this homogeneous solution. (As per Clogged ESP Cell Condition & Stickiness of the Dust Particles in It).
  3. Remove the ESP Cell (Stack) from this solution and use a spray or gun to wash it with normal high-pressure water for 15-20 minutes. (The pressure limit is not more than 4 bars.)
  4. After properly washing the ESP cell, you must dry the ESP cell (stack) in direct sunlight or using compressed air (the pressure limit is not more than 3 bars).
  5. Dry it completely, make sure, and then install Stack in the ESP Cabinet.

Material Required:

  • Filter ON -1 Cleaning Powder
  • Large- volume water tanks open on top with drain provision at bottom.
  • Dedicated cleaning location and drainage facility.
  • High-pressure water
  • Compressed air
  • Material Handling Provision: Forklift/stacker, trolley, etc.

Mechanical/Centrifugal Oil Mist Collectors - Maintenance Procedure:

Every 1000 hours of operation and more often if the working conditions require it, clean the exterior and the suction mouth of the mist collector.

Programmed Maintenance:

In order to ensure the maximum efficiency of the air filter, it is necessary to undertake preventive programmed maintenance at regular intervals.

Filter, Seals, and Rotors Maintenance:

Cleaning the filters:

Careful and regular cleaning of all the internal parts (shell, drainage pipe, drainage ring, etc.) ensures high performance and long life of the air filter.

It is also important to routinely inspect the inside of the centrifuge and the turbine blades to remove any potential deposits of metal fragments, sludge, or other debris that might lead to a loss of balance in either the centrifuge or the turbine. to get rid of any potential deposits of sludge, metal particles, or other debris that might throw the centrifuge or turbine out of balance.

For the internal cleaning of the air filter and the rotators (either turbine or centrifuge), use a clean brush saturated in a mild industrial detergent solution. Alternatively, standard liquid soaps can be used. Should the dirt be very resistant, it is advisable to remove the rotor, use an alternative cleaning solution, and allow the centrifugal device to dry in the open air or dry with a jet of compressed air.

Structural Checks Required Yearly:

Each year:

Verify that the anti-vibration joints' nuts are securely tightened.

Every year:

Check the condition of the safety tie rods.
Check the good condition of the mist collector shell.

Every 4 years:

Replace the anti-vibration joints.

Benefits of Routine Maintenance of Oil Mist Collector Systems:

  • Worker safety and well-being.
  • Organizations bound by compliance.
  • Durability of Equipment
  • Operational Efficiency

In conclusion, centrifugal and ESP filter cleaning guidelines must be adhered to, and routine maintenance of oil mist extractors is crucial. This will allow workers to breathe clean air and extend the equipment's lifespan in compliance with regulatory standards and regulations.

Please contact us if you have any questions about fume extraction maintenance.
Email us: customersupport@filter-on.com.

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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Shed No.1, Saiprasad Complex, Survey No 78/1, Aura Industrial Cluster Near Shivkamal Industrial Estate, Off NDA Road, Shivane,  PUNE - 411 023

Our Solutions

Soldiering & Laser Marking Fumes

Welding, Brazing & Gouging Fumes

Laser & Plasma Cutting Fumes

CNC Machining & Mist Extractions

Grinding & Buffing Fumes

Melting & Heat Treatment Fumes

Turnkey Clean Air Project Solution

Kitchen Fumes Filtration

Quick Links

Home

Gallery

Careers

Terms & Conditions

Privacy Policy

Disclaimer

FAQ's

Contcat Us

Get In Touch

Enter your email and receive the latest news from us.

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Make- in- India
Swachh Bharat Mission Logo

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