Planning for Clean Air in Industrial Workspaces

An efficient fume extraction system is critical in industries where the different processes release harmful airborne pollutants. For such areas, a well-planned fume control system and layout ensures cleaner air and also improves safety, reduces health risks and keeps equipment in a better condition. However, creating such a well planned system requires meticulous planning based on the workflow, equipment and type of pollutants.

Assessment of the Site and Operation

The first step is to understand the layout of the facility and identify the points where fumes are generated. A detailed walkthrough of the workspace can help to list out areas where fumes, smoke, mist, or dust are generated. Identify high-risk zones like welding bays, soldering stations, CNC machines, and chemical mixing areas. Knowing the exact locations of pollutant sources helps determine where extraction systems should be placed.

Choose the Right Type of Extraction System

The choice of system depends on the type and volume of fumes you need to remove. Common options include:

• Local Exhaust Systems
  • These systems capture fumes right at the source using hoods or arms. They are best for targeted processes like soldering, welding, or grinding.
• Centralized / Semi-Centralized Ducted Systems
  • These use ductwork to connect multiple workstations to a central filtration unit. Ideal for large facilities where multiple operations run simultaneously.
• Portable Units
  • For smaller setups or mobile applications, portable fume extractors offer flexibility and ease of use.

Map the Airflow Path

Plan how the contaminated air will move through the system. The airflow should move directly from the fume source to the extraction unit without obstruction. Avoid long, winding ducts that create resistance and reduce suction power. Keep duct lengths short and use smooth bends to improve airflow efficiency.

Position the Extraction Points Properly

Place the suction hood or fume extraction arm as close as possible to the fume generation point. Ideally, the fumes should be captured before it can spread into the general breathing space and atmosphere within the shopfloor. The suction hood should be placed as close as possible to the generation point without disturbing the operation, ideally within 8 – 10 inches. This is to ensure maximum efficiency of extraction of the fumes and smoke. For example, a welding fume extractor will require that the hood be placed within 10 inches to avoid disrupting the operation but a soldering fume extractor can have the hood placed up to 6 inches from the fume generation point.

Choose the Right Filter Type

Different applications require different filters:

• Use HEPA filters for very fine dust or particles.
  
• Use electrostatic filters for smoke and mist from oil-based processes.
  
• Use carbon filters for chemical vapors or odors.
  

Make sure the filtration system matches the type of air pollutants your processes generate.

Ensure Proper Exhaust or Recirculation

Decide whether the filtered air should be vented outside or recirculated back into the workspace. Recirculation saves energy but should only be used when the air is thoroughly cleaned. Venting outside is recommended when dealing with chemical fumes or where regulations demand it.

Allow for Maintenance and Accessibility

Design the system so that all filters, hoods, and ducts are easy to access for cleaning and servicing. Avoid placing ducts behind heavy equipment or in tight corners. Regular maintenance ensures the system runs efficiently and avoids breakdowns.

Follow Local Safety and Air Quality Regulations

Make sure your layout meets safety codes and environmental rules. Different regions have different standards for air quality and workplace ventilation. Consulting with a qualified air quality expert or supplier ensures compliance from the start.

Conclusion

Designing a layout for a fume extractor is not just about placing machines and ducts. It requires a clear understanding of where pollutants are generated, how air moves through the space, and how to capture it effectively. A well-designed layout protects your workers, keeps your processes clean, and helps your business stay compliant with health and safety standards. Planning your layout right from the beginning will lead to long-term savings and a healthier work environment.

Soldering in Electronics Manufacturing

Soldering is a critical process in electronics manufacturing and various soldering methods are used to join components on circuit boards with precision. However, the process of soldering also leads to generation of potentially harmful fumes that are released from the solder and flux. Soldering fume extractors can help to capture and control the fine particulate matter in the soldering fumes and are used to maintain a clean and safe working environment by removing the harmful fumes at the source.

Dangers of Soldering Fumes

Soldering fumes are generated from the solder and flux and contain extremely harmful chemicals like rosin and lead. While the volume of fumes is not very high, they are highly toxic and regular exposure can lead to a multitude of issues including eye and throat irritation, headaches, and in some cases, long-term respiratory issues. Workers near the stations are posed with the highest risk and it becomes critical to include soldering fume extractors to protect the health of the workers.

How a Soldering Fume Extractor Works

A typical soldering fume extractor works in 3 steps:

1. Capture of Particulate Matter: The generated fumes are captured by means of a suction hood positioned close to the fume generation point, without disrupting the work or the worker.
2. Filtration of Harmful Particles: The fumes consist if fine particulate matter that get filtered out by means of a physical filter or electrostatic filtration. The FumeKiller® makes use of electrostatic filtration to filter the fumes.
3. Release of filtered air: The filtered air is then released through the system outlet, either back into the shop floor or to the outside by means of ducting.

Type of Fume Extractor Required

Depending on the size of the operation, available space among other factors, different types of fume extraction systems are available to control soldering fumes.

1. Portable Fume Extractor: These units are small and are better suited for smaller soldering operations for individual workstations.
2. Semi-Centralized / Centralized Fume Extractor: This type of system is suited for high volume production lines and multiple workstations are connected to a single fume extractor unit.
3. Type of Filter: Soldering fume extractor manufacturers may use different types of filters. The units may use either physical filters like HEPA filters or electrostatic filter modules.

The type of fume extractor required may be finalized based on the specific requirement.

Benefits of a Soldering Fume Extractor

In addition to protecting worker health, fume extractors help maintain compliance with safety regulations set by local and national agencies. These regulations often set limits on permissible exposure to airborne contaminants. Installing and maintaining effective fume extraction systems helps companies meet these legal requirements and avoid penalties, while also showing a commitment to employee safety and workplace standards.

Clean air not only protects people, but also contributes to a better working environment. Workers are more focused and productive when they are not breathing in irritants. Equipment and sensitive components also benefit from reduced contamination, which can improve overall product quality. Over time, companies that invest in proper air extraction see fewer health-related absences and reduced equipment maintenance costs, making it a smart operational decision as well.

Soldering fume extractors have become a standard part of electronics manufacturing. They are simple in design but critical in function, and they support both health and performance in the production process. As the industry continues to grow and place more emphasis on safety and quality, the role of fume extraction systems will remain central to responsible manufacturing practices.For more information on soldering fume extraction systems or in case of any requirement for the same, please get in touch with us today.

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:

1. Reduction in air quality within the shopfloor.
2. Mist settling within the gaps on the machine which may lead to breakdowns and system failures.
3. 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.