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Robotic Welding Fume Extraction Systems: How They Work & Why They Matter

Robotic welding fume extractors are essential components of modern manufacturing. Robotic welding fumes are extremely hazardous for workers in industries such as automotive components and material handling, where automated welding lines are common.

Since these welding lines operate continuously, it is crucial to mitigate the risks and protect workers. In this blog post, we’ll discuss how robotic welding fume extractors work, why they’re important for maintaining clean air in industrial environments, and how Filter ON can help.

Let’s get started!

Introduction to Robotic Welding Fumes

Robotic welding fumes vary in composition and can seriously harm workers who operate or maintain robotic welding cells. These fumes contain pollutants such as PM2.5 and PM10, which are dangerous when inhaled over time.

How robotic welding fumes generated?

Robotic Welding fumes are generated rapidly you can check and see in this below video for clarification, This shows how robotic welding fumes are generated

Potential Danger Due to Robotic Welding fumes:

In industrial workplaces, inadequate air filtration and fume extraction pose significant health risks, including respiratory diseases and chronic illnesses. Workers exposed to fumes without proper systems, like a Robotic welding fume extractor, are vulnerable to conditions such as bronchitis and cancer, which negatively affect their morale and well-being. Poor air quality can also lead to discomfort, decreased concentration, and productivity loss. Furthermore, industrial fumes can damage equipment, increase maintenance costs, and trigger non-compliance with health regulations, which impairs a company's reputation and environmental responsibility. Effective solutions like Robotic welding fume extractors are essential for maintaining air quality and ensuring worker safety. Learn more about potential danger due to Robotic Welding Fumes in our Comprehensive Guide to Industrial Air Filtration.

Why Welding Robots Still Need Fume Extraction:

Even though robotic welding is automated, it continuously generates fumes.

- Robots work without breaks, so fumes accumulate rapidly.
- Welding cells whether open or closed allow fumes to spread quickly. In open setups, they can contaminate the entire workspace.
- Without proper filtration or exhaust systems, air quality deteriorates, productivity drops, and workers’ health suffers.

How Does a Robotic Welding Fume Extraction System Work?

Robotic fume extractors operate based on the volume of generated fumes and the rate of clean air output. Two main extraction methods are used:

1. Source Capture Method

In this method, a suction arm captures fumes directly from the welding source.
Portable extraction systems are ideal for large welding jobs where welders move around frequently.

2. Ambient Extraction Method

Here, stationary fume extraction systems with canopies, hoods, and ducting are used. They capture fumes from the entire robotic welding cell and filter them through a central system.

Common Pollutants in Robotic Welding Extractions

Robotic welding fumes contain various pollutants such as metal fumes, ozone, and gases.

Metal Fumes: These include fine particles (PM2.5 and PM10) that are highly hazardous to human health. Robotic welding fume extractors are essential to remove them.
Ozone and Other Gases: Ozone and other gases formed during welding can cause eye irritation and respiratory problems. Fume extraction is necessary to remove these as well.

Learn more about industrial pollutants in our Comprehensive Guide to Industrial Air Filtration.

Key Components of a Robotic Fume Extraction System

A robotic fume extraction setup typically includes:

Clean air system (ESP system)
Filters
Hoods and canopies
Ducts
Blower unit
Electrical panel

Hoods and Canopies

These structures capture fumes precisely to prevent exposure and health risks.

Ducting

Carries fumes from the welding area to the filtration system.

Filters

The most critical component — filters remove harmful smoke and fine particles.

Suction Hood

Draws in fumes using a blower motor. The size depends on the type of welding machine or setup.

Blower or Motor

Generates the suction force required for fume capture.

Electrical Panel

Controls and monitors the extraction system.

ESP Stacks

Electrostatic Precipitator (ESP) stacks use ionization to capture and remove fine particles efficiently.

Role of Electrostatic Precipitators (ESP) in Robotic Welding Fume Extraction:

An ESP filtration system cleans air containing welding fumes, smoke, and fine dust.

How it works:

Fume Collection: Polluted air is drawn from the robotic welding cell.
Electrostatic Charging: The air passes through an electrostatic field, charging the particles.
Particle Removal: Charged particles adhere to oppositely charged plates, removing even submicron particles (as small as 0.01 µm).
Clean Air Output: Fresh air is released back into the workshop or outside.
Easy Maintenance: Washable metallic filters mean no frequent replacements and low operating costs.
Efficiency: ESPs are highly effective and maintain a clean, safe working environment.

Benefits of Robotic Welding Fume Extraction:

Improved Air Quality & Worker Safety
Clean air reduces breathing problems, eye irritation, and other health risks improving overall productivity.
Better Equipment Performance & Reduced Downtime
Washable ESP filters reduce maintenance needs, keeping systems running smoothly.
Compliance with Safety Standards
Systems must comply with OSHA and CPCB standards.
Read more about Fume Extraction Standards & Regulations

Choosing the Right Extraction System

Selecting the right extraction system ensures worker safety and operational efficiency. Consider:

Air Volume: Determines the size and capacity of the system.
Robot Layout: Open or closed cell designs require different solutions.
Type of Welding: MIG, TIG, laser, or plasma welding all produce different fume levels.

Centralized vs. Individual Extraction Units

Centralized Systems: Ideal for large plants with multiple robotic welding cells.
Individual Units: Offer flexibility and source-level fume capture.

Smart Controls and Automation Integration

Modern fume extraction systems feature smart controls, such as remote monitoring, automatic shutoff, and real-time alerts. Ensure these features are considered when selecting your system.

Filter ON’s Solutions for Robotic Welding

Filter ON is a leading Indian provider of industrial air filtration and fume extraction systems, working toward “Mission Zero Pollution” for over 40 years.

We offer over 70 clean air solutions across welding, oil mist, dust collection, and kitchen scrubber applications. For robotic welding, they provide both individual and centralized ESP-based systems.

Why ESP-Based Systems Are Ideal for Robotic Welding

Compared to cartridge filters, ESP systems offer major advantages:

Zero filter replacement cost
Lower power consumption
Higher filtration efficiency
Washable filters for long-term use

Filter ON’s ESP-based systems deliver proven results for both individual and centralized setups.

Custom Design and After-Sales Support

Every plant has unique requirements. Filter ON provides custom-designed solutions backed by decades of experience and strong after-sales support, ensuring reliable system performance.

Conclusion

ESP-based robotic welding fume extractors offer high efficiency, low maintenance, and long-term value. With over 40 years of expertise, Filter ON continues to deliver innovative, customized, and sustainable clean air solutions for industries across India.

Contact Filter ON at marketing@filter-on.com to design a robotic welding fume extraction system customized for your factory setup.

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

Breathable Workspaces: Understanding PM 2.5 and PM10 Pollution

Breathable Workspaces: Understanding PM 2.5 and PM10 Pollution, Knowing Safety Limits, and Implementing Solutions for Worker Health

Today, air pollution is a very sensitive subject for everyone. In every country, cities, and now small villages, are also affected by air pollution due to various pollutants. PM2.5 and PM10 are two of the major pollutants. In industrial environments, PM2.5 and PM10 are present due to various industrial processes. In this article, we are discussing PM2.5 and PM10 as pollutants, their impact on industrial workers, safety and solutions to overcome pollution from them, and government norms and regulations about PM2.5 and PM10 in an industrial context.

What are PM 2.5 and PM 10?

Particulate matter (PM) is a fine, microscopic matter suspended in air or water. PM2.5 and PM10 are the two types of particulate matter.

What is PM2.5?

Particulate Matter (PM) 2.5 is a very small particulate matter with a microscopic size of 2.5 or smaller.

What is PM10?

Particulate Matter (PM) 10 is a small particulate matter with a diameter of a microscopic size of 10 or smaller.

PM2.5 and PM10 as pollutants

PM2.5 and PM10 are small particulate matter that is totally microscopic, so they are inhaled by humans.

PM2.5 Sources

Natural Sources:

>> Forest Fires
>> Volcanic Eruptions
>> Earthquakes

Artificial Sources

Industrial Sources :

Industrial sources include paper pulp industries, oil refineries, brick kilns, power plants, municipal waste treatment plants, industrial fossil fuel burning, and gasoline sources such as sulfur dioxide and nitrogen oxide.

Household Sources :

>> Construction Sites
>> Smoking
>> Cooking, Frying, and Not Maintaining Kitchen Chimneys
>> Wood Burning
>> Biomass Burning

Emissions

>> Emissions from Vehicles

PM10 Sources :

There are various sources of PM10 pollution.
The natural sources include sea salt, dust, etc., whereas man-made sources are as follows:
smoke, dust, and dirt from unsealed roads, construction, landfills, and agriculture
pollen
mold
smoke from wildfires and waste burning

Industrial Sources

>> materials handling
>> crushing and grinding operations
>> power generation

In the home, PM10 comes from many sources, some of which are as follows:

>> outdoor sources leaking in through spaces around doors and windows

>> stoves

>> space heaters

Apart from these sources, some of the industrial processes also produce PM2.5 and PM10.

Welding :

Welding is a general process that is carried out in most manufacturing industries. During the welding process, PM2.5 and PM10 are generated when hot metal vaporizes, cools, and condenses into small, solid metal particles. Welding aerosols can be coarse (PM 2.5–10) or fine (PM 0.1–2.5). Welding produces visible smoke that contains harmful metal fumes and gas by-products. Welding workers are exposed to significant amounts of the metal fume PM2.5 during the welding process.

Plasma Cutting-

Plasma cutting generates the highest concentrations of PM2.5. Most aerosols generated during plasma arc cutting are PM 2.5. The fumes and gases generated by plasma cutting depend on whether the cutting is dry or wet.

Some of the other processes are also responsible for PM2.5 and PM10 generation, like diesel exhaust.

Health Effects of PM 2.5 and PM 10.

Particulate Matter (PM) 2.5 and 10 have very serious health effects on humans, mainly those who are most in contact with them. In industries, these pollutants are generated from various industrial processes such as welding, brazing, cutting, etc. So the adverse health effects of these pollutants are as follows:.

Short-term health effects of PM10 can include:

>> Difficulty breathing
>> Coughing
>> Eye, Nose, and Throat Irritation
>> Chest tightness and pain
>> Fatigue
>> General Respiratory Discomfort

Long-term exposure to PM10 can cause more serious health concerns, such as:

>> Lung tissue damage
>> Asthma
>> Heart Failure
>> Cancer
>> Adverse birth outcomes
>> Chronic obstructive pulmonary disease (COPD)
>> Premature death

Health Effects of PM2.5

>> Short-Term Health Effects of PM 2.5
>> Irritation of the throat and airways
>> Coughing
>> Breathing Difficulty

Long-Term Health Effects of PM 2.5

>> Heart and lung disease
>> Bronchitis
>> Emphysema
>> Nonfatal heart attacks
>> Irregular heartbeat
>> Asthma and more intense flare-ups
>> Decreased lung function
>> Early death

Safe Limits for PM 2.5 and PM 10.

There are two types of absorption limits for PM 2.5 and PM 10, as follows:

>> General (Ambient Air) Absorption Limits for PM2.5 and PM 10
>> Industrial Processing Absorption Limits for PM2.5 and PM 10

General (Ambient Air) Absorption Limits for PM2.5 and PM 10

As per CPCB India’s Central Pollution Control Board’s norms, the general (ambient air) absorption limits of PM 2.5 and PM 10 are as follows:

Industrial Process Absorption Limits for PM 2.5 and PM 10.

The industrial process absorption limits for PM2.5 and PM10 as per OSHA standards are as follows:

Solutions to PM 2.5 and 10 in the Industrial Environment

Many countries seek to reduce PM2.5 and PM10 air pollution. For example, in 2019, India joined the United Nations Climate and Clean Air Coalition with the stated goal of reducing particulate matter pollution by 20 to 30 percent by 2024. The country launched the National Clean Air Program in mid-2019.

Solutions on PM 2.5 and PM 10 for Industries

Use Eco-Friendly Process Materials: Industries must use eco-friendly process materials for their processes, such as in welding, where we must use water-based fluxes or electrode coatings, which can reduce the environmental impact of welding. These materials help reduce the fumes generated and waste produced during the welding process.

Use Industrial Air Filtration Systems: Industrial air filtration systems such as welding fume extractors, oil mist collectors, laser marking fume extractors, soldering fume extractors, and dust collectors must be used for air filtration in an industrial work environment to reduce the impact on workers of PM 2.5 and PM 10.

Use Monitors for Measurement of PM2.5 and PM10 Pollution in Industries: Use PM2.5 and PM10 monitors for measurement of the severity of workers health.

Use PPE Equipment While Working: Use personal protective equipment like masks, helmets, hand gloves, and PPE attire while working to reduce PM 2.5 and PM 10 exposure.

Reduce Burning Fossil Fuels: Reducing fossil fuel use and switching over to renewable energy sources can reduce the exposure to PM2.5 and PM10 in industries because the burning of fuels is a major source of PM2.5 and PM10 pollution.

Reducing the use of wood burning: reducing the burning of wood is the best solution to reducing PM2.5 and PM10 pollution.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. 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 Pune, Delhi, Bangalore, or Chennai locations.