2Jun2025

Success of FumeKiller® as an Oil Mist Collector at Nexteer

Introduction: Extraction of Oil Mist from CNC Machining Process

The FumeKiller® finds use across a variety of applications. Primarily used as a welding fume extractor or soldering fume extractor, the FumeKiller® also finds use as an effective oil mist collector. Following are the details of a successful application of the FumeKiller® for the extraction of oil mist generated from a CNC machining process.

The Challenge: Issues due to Oil Mist in the Shop Floor

Nexteer, a well known and established player in the manufacturing industry was facing an issue commonly faced during the CNC machining process – oil mist.

The process involved the use of neat cutting oil during the machining process which led to the generation of oil mist. The mist would escape into the shopfloor which led to various issues, including:

Reduction in air quality within the shopfloor.
Mist settling within the gaps on the machine which may lead to breakdowns and system failures.
Loss of oil mist means loss of usable neat cutting oil over time.

Any solution provided to the customer would need to be designed with all the above problems in mind and effectively solve each issue.

The Solution: FumeKiller® model FK2000EM

To address both the primary and secondary issues, a careful study of the work area was done before suggesting a FumeKiller® model FK2000EM for the capture and control of the generated oil mist. The unit was to be mounted on a 6.5 ft. pipe stand positioned close to the CNC machine. This positioning would also provide an additional advantage of being able to collect the filtered oil mist from a drain point provided on the FumeKiller® unit.

The logic used for this solution is primarily based on the concept of mist evacuation where the entire volume of air within the CNC machine is evacuated within a certain time, usually 5-10 seconds. This ensures that when the doors of the machine are opened there are no mist particles that escape into the shopfloor.

Results and Impact: Successful Implementation of FumeKiller®

The implementation of the FumeKiller® was a success which allowed for multiple benefits to our client:

Improvement in Air Quality: The complete volume of air within the CNC machines, which would include the generated oil mist, was being evacuated before the doors were opened and therefore, with no release of oil mist into the shopfloor, it resulted in a significant improvement in the air quality.
Operational Efficiency: The FumeKiller® model FK2000DPEM is a single oil mist collector unit that was equipped with a dual-pass filtration system, allowing for greater efficiency of filtration and therefore, even cleaner air being released into the shopfloor.
Cost Savings: Because the filtered oil could be collected and reused, the neat cutting oil for the process was more efficiently and economically used, which resulted in a direct reduction in operational costs.
Regulatory Compliance: The successful implementation of the FumeKiller® as an oil mist collector resulted in the customer meeting the required air quality standards within the shopfloor.

Conclusion: The Capability of FumeKiller®

The successful execution of the project serves as another example of the capability and versatility of the FumeKiller® as a fume extractor as well as an oil mist collector. It can be stated with confidence that the FumeKiller® is probably one of the most effective air pollution control systems currently available. For more details about the FumeKiller®, visit our website or you can get in touch with us for any requirement you may have for air pollution control solutions.

12May2025

Benefits of Using a Fume Extractor in Industrial Applications

The air quality inside modern workplaces stands equally important to the tasks employees perform. The production of dangerous fumes and smoke and dust and mist results from various industrial processes including welding and soldering and grinding and chemical processing. Uncontrolled pollutants create dangerous health risks for workers while shortening equipment life and establishing hazardous working conditions.

The solution to this problem are fume extractors.

A fume extractor functions as an essential component of air pollution control systems because it captures dangerous particles and gases at their origin before they can escape into the surrounding environment. These systems provide multiple valuable advantages to industrial operations. Let’s break down the major benefits of using a fume extraction system in industrial applications.

Protecting Worker Health:

Protecting the health of workers is one of the primary applications of a fume extractor.

Industrial processes like welding, soldering, brazing etc release pollutants such as metal fumes, flux gases and fine particulate matter.

Inhaling these can lead to a range of health issues including:

Respiratory problems
Skin and eye irritation
Long-term illnesses like asthma or lung disease
Exposure to toxic metals such as lead or cadmium

By removing the pollutants right at the source, the air within the shop floor remains relatively clean and the risk of health hazards for employees are significantly reduced. Fume extraction systems are primarily used for this purpose.

Ensuring Regulatory Compliance

Meeting regulatory compliance laws are a must for most industrial processes.

In India, bodies such as the Central Pollution Control Board (CPCB) set the guidelines to be followed for companies to meet specific workplace and environmental safety.

In addition to meeting these regulations, installing an efficient fume extraction system can help to demonstrate a company’s commitment to responsible and sustainable operations.

Improving Air Quality in the Workspace

Improvement in air quality not only benefits worker health but a cleaner workspace in general.

By using a welding fume extractor or soldering fume extractor, pollutants that would normally settle on the machines and other flat surfaces get extracted and filtered, leading to cleaner spaces.

Additionally, the cleaner air within the shop floor also helps improve visibility and creates a more comfortable working environment, leading to higher morale and better retention rates among employees.

Protecting Equipment and Reducing Maintenance

As previously mentioned, air borne contaminants can settle on machinery and cause significant harm.

Pollutants like oil mist and fine dust can cause significant wear and tear on sensitive equipment which can lead to malfunctions and breakdowns over time. This delays the industrial processes and can cause significant increase in the maintenance costs. By using a fume extraction system to keep the air clean, companies can reduce maintenance costs, increase equipment life and reduce downtime.

Supporting Sustainable and Eco-Friendly Operations

Sustainability is a buzzword used very commonly in the industrial world and the expectation for companies to reduce their carbon footprint and environmental impact is ever growing.

It is obvious how air pollution control systems like fume extractors and dust collectors can contribute toward this goal.

The pros of using a good fume extraction system far outweigh the cons and the benefits of using these systems makes them essential for any modern industrial facility. We will continue to explore these systems along with specific applications and technologies. Stay tuned for more.

5May2025

What is a Fume Extraction System?

Keeping a clean and safe workplace is not only a recommended practice, but also a must in today’s industrial world. The prevalence of airborne pollutants like fumes, smoke, and fine particles has grown significantly with the use of operations like welding, soldering, machining, and chemical treatment. A fume extraction system is essential in this situation.

Understanding the Basics

A specialized air pollution management method called a fume extraction system is made to catch and eliminate dangerous airborne pollutants at their source. These systems’ main purpose is to stop harmful gases from spreading onto a manufacturing floor, guaranteeing cleaner air for employees and adherence to safety and environmental standards.

These systems are essential to maintaining the best possible air quality in a variety of industries, including electronics, pharmaceuticals, automotive, and aerospace. A well-designed fume extractor is the first line of defence against dangerous emissions, whether they be particles from soldering or smoke from welding.

Why Fume Extraction is Critical

Many heavy metal fumes and gases are emitted into the air during welding, soldering, brazing, and other related processes. Serious health hazards such as metal fume fever, chronic bronchitis, respiratory problems, and even long-term organ damage can result from breathing in these fumes.

Not only do these fumes harm employees, but they also affect machinery, reduce visibility, and create a hazardous working environment. An effective welding fume extractor or soldering fume extractor improves worker health, boosts productivity, and extends the life of equipment.

How Does a Fume Extraction System Work?

Fume extraction system works in 3 steps:

Capturing fumes / smoke directly at the generation point using hoods, extraction arms or enclosures.
Filtering the contaminants from the captured air using high efficiency filters like HEPA or electrostatic filters.
Releasing the filtered air safely back into the shop floor or to the outside atmosphere through ducts or vents.

Modern, specially made fume extractors from Powertech Pollution Controls guarantee effective operation in a range of industrial applications. For example, our FumeKiller® is an electrostatic filtration system that removes fumes silently and efficiently without requiring regular filter changes.

Applications of Fume Extractors

Based on the application, the type of fume extraction system may vary. For example, the FumeKiller® finds use in both welding as well as soldering and the design of the system varies based on the application.

Welding Fume Extractor: Ideal for MIG, TIG, arc welding, and plasma cutting, the systems are more heavy-duty and focus on capturing the fumes from the source.
Soldering Fume Extractor: Used in electronics and electrical manufacturing, these systems are compact and remove fine solder smoke and flux fumes to protect technicians and delicate components.

Benefits of Using a Fume Extraction System

Improved Air Quality: Removal of harmful fumes leads to a healthier working environment.
Regulatory Compliance: Meet international air quality standards with ease.
Employee Safety and Retention: A cleaner environment means higher job satisfaction and reduced health risks.
Equipment Longevity: Clean air reduces the accumulation of residue on sensitive machinery.
Energy Efficiency: Recirculating systems like Powertech’s FumeKiller® save on HVAC costs.

Why Choose Powertech Pollution Controls?

Established in 1996, Powertech Pollution Controls is a pioneer in the field of air pollution control solutions in India. Our fume extraction systems are known for:

Custom Design: Tailored to meet specific process requirements.
High Quality: Built to industrial standards with premium-grade components.
Excellent Service: End-to-end support from design to installation and maintenance.
Eco-Friendly Solutions: Designed to minimize environmental impact while maximizing efficiency.

Whether you’re looking for a welding fume extractor, soldering fume extractor, or a multi-process solution, Powertech provides industry-leading systems that prioritize safety, performance, and sustainability.To learn more about our fume extraction systems or to request a site evaluation, contact us today

30Jun2024

How Custom Solutions from Powertech Pollution Controls Benefit Your Business

In today’s industrial landscape, air pollution control is a critical concern for businesses across various sectors. Ensuring clean air within industrial environments is not only a regulatory requirement but also essential for the health and safety of workers, the longevity of equipment, and overall operational efficiency. At Powertech Pollution Controls, we understand that each industrial operation has unique challenges and requirements when it comes to managing air quality. This is why we specialize in providing custom solutions tailored to meet the specific needs of our clients.

Custom solutions in air pollution control offer several distinct advantages over standard, one-size-fits-all systems. These advantages stem from the ability to design and implement solutions that address the unique characteristics of each industrial process and environment. By focusing on customization, Powertech Pollution Controls ensures that our clients receive the most effective and efficient air pollution control systems possible.

One of the primary benefits of custom air pollution control solutions is the precise targeting of specific pollutants. Different industries generate different types of pollutants, ranging from dust and smoke to fumes and mist. A custom solution allows for the selection and combination of technologies best suited to capture and neutralize these specific contaminants. For instance, a welding shop may require an advanced welding fume extractor like our FumeKiller®, while a food production facility might need a high-efficiency dust collector such as the DustBag® Reverse-Pulsed-Jet. By tailoring the system to the exact pollutants present, we can ensure maximum effectiveness and compliance with environmental standards.

Another significant advantage of custom solutions is the optimization of system performance and energy efficiency. Standard systems often operate under suboptimal conditions because they are not specifically designed for the particular requirements of a given industrial process. Custom solutions, on the other hand, are engineered to match the exact airflow, pressure, and filtration needs of the operation. This results in more efficient capture and removal of pollutants, reducing energy consumption and operational costs.

Custom air pollution control solutions also offer enhanced flexibility and scalability. As industrial processes evolve and production demands change, the ability to modify and expand air pollution control systems becomes crucial. A custom-designed system from Powertech Pollution Controls can be easily adapted to accommodate new processes, increased production volumes, or changes in regulatory requirements. This flexibility ensures that your investment remains valuable and effective over the long term, providing a future-proof solution to air quality management.

At Powertech Pollution Controls, our commitment to providing custom solutions begins with a thorough understanding of our clients’ needs. Our process involves a detailed assessment of the industrial environment, including site visits, detailed study of the application and pollutants generated, and consultations with key personnel. This comprehensive analysis allows us to identify the specific pollutants and operational requirements that need to be addressed. Based on this assessment, we design a tailored solution that incorporates the most appropriate technologies and configurations.

Our custom solutions encompass a wide range of technologies, including electrostatic precipitators, baghouse filters, centrifugal mist collectors, and advanced fume extraction systems. Each technology is selected and configured to work seamlessly with the others, creating an integrated system that delivers superior air pollution control. We also provide complete installation and commissioning services, ensuring that the system is correctly implemented and fully operational from day one.

Post-installation, Powertech Pollution Controls offers ongoing support and maintenance services to ensure the continued effectiveness of our custom solutions. Regular maintenance, performance monitoring, and timely upgrades are essential for maintaining optimal system performance. Our dedicated service team is always available to provide technical support and address any issues that may arise, ensuring that your air pollution control system operates reliably and efficiently over its entire lifespan.

For more information on how Powertech Pollution Controls can develop a custom solution for your business, please visit our product page or contact us here.

30Jun2024

Case Study: How FumeKiller® Improved Air Quality in a Welding Shop

In the industrial sector, maintaining air quality is a critical concern, especially in environments where hazardous fumes are prevalent. Welding shops, in particular, face significant challenges due to the production of toxic fumes and particulates during welding processes. Poor air quality not only poses health risks to workers but also affects overall operational efficiency. This case study explores how Powertech Pollution Controls’ FumeKiller® significantly improved air quality in a welding shop, enhancing both worker safety and productivity.

The client, a medium-sized welding shop specializing in the fabrication of automotive components, was grappling with severe air quality issues. The shop employed over 30 welders who worked in close proximity to each other, increasing the risk of exposure to harmful fumes. The management had received numerous complaints from employees about respiratory problems, eye irritation, and overall discomfort.

Recognizing the urgency of the situation, the team from Powertech Pollution Controls completed a comprehensive study of the application and it was decided that the FumeKiller®, due to its advanced technology, superior filtration capabilities, and proven track record in similar industrial settings, would be used as welding fume extractor to provide a solution for the issue.

The FumeKiller® is an electrostatic fume extraction system designed to capture and neutralize welding fumes at the source. It utilizes a combination of mechanical filtration and electrostatic precipitation to remove even the finest particulates and gaseous pollutants from the air. The system is equipped with high-efficiency filters that trap large particles, while the electrostatic precipitator charges and collects smaller particles, ensuring comprehensive air purification.

The entire system was designed such that each welding station would be equipped with a single portable FumeKiller® unit, which would be equipped with a flexible extractor arm to ensure that the fume extraction hood was placed as close as possible, ideally within 8 – 10 inches, from the fume generation point. This system would ensure that the FumeKiller® could be repositioned at any point of time in case the welding station is moved to a different location.

Within weeks of installation, the welding shop began to experience noticeable improvements in air quality. The FumeKiller® effectively captured and removed welding fumes, significantly reducing the concentration of airborne pollutants. Workers reported a marked decrease in respiratory issues and eye irritation, and overall comfort levels improved. The improved air quality also contributed to a more pleasant and productive working environment, boosting employee morale and satisfaction.

In addition to health benefits, the FumeKiller® provided substantial operational advantages. The reduction in airborne particulates minimized equipment malfunctions and maintenance requirements, leading to lower operational costs and increased efficiency

Moreover, the FumeKiller®’s advanced filtration system ensured that the welding shop complied with stringent environmental and safety regulations. By maintaining air quality standards, the shop avoided potential fines and legal issues, reinforcing its commitment to worker safety and environmental responsibility.

The success of the FumeKiller® as a portable welding fume extractor underscored the importance of investing in high-quality air pollution control solutions. The positive impact of the installed welding fume extractors in this welding shop serves as a compelling example for other industrial facilities facing similar air quality challenges. It demonstrates that with the right technology and expert support, it is possible to create a cleaner, safer, and more efficient work environment. For more information about the FumeKiller® and other air pollution control solutions, visit our product page or contact us today.

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