Delivering Efficient Fume Control for Simultaneous Welding

Powertech Pollution Controls recently completed a project where the requirement was a fume extraction system that can manage to capture and control fumes from two welding applications running at the same time. Welding fumes, if not controlled, reduce air quality, affect worker health, and settle on nearby equipment. To meet this need, our team supplied the FumeKiller model FK3600VEM, fitted with twin flexible extractor arms for effective source capture.

The Challenge: Controlling Fumes from Dual Welding Stations

In this case, the client required a single solution that could capture fumes from two active welding setups. Using two separate units would have consumed more space, energy, and cost. The challenge was to provide one portable system that could extract fumes efficiently from both stations without affecting the welding process.

The Solution: Portable FK3600VEM with Twin Arms

The FK3600VEM is a high-performance electrostatic fume extractor designed for industrial use. For this project, the unit was equipped with twin flexible extractor arms, each with an adjustable suction hood.

Key Features of the Solution

• Twin Extractor Arms: Allowed simultaneous capture of fumes from two welding stations.
  
• Flexible Positioning: The arms could be moved easily to place the hoods close to the fume source, ensuring effective capture without disrupting the welders’ workflow.
  
• Portability: The unit could be moved across the shop floor to different areas, offering flexibility for changing production needs.
  
• Electrostatic Filtration: Captured fine welding fumes and released clean air back into the workspace.
  

The Outcome: Cleaner Air and Higher Efficiency

After installation, the client reported significant improvement in workplace air quality. The welding fume extractor successfully handled fumes from two welding stations at once, reducing exposure risks for operators and keeping the shop floor cleaner. The use of a single portable unit instead of two separate systems also saved floor space and lowered operational costs.

Conclusion

This project demonstrates how the FumeKiller can be adapted to meet specific client needs. By equipping the unit with twin flexible arms, Powertech Pollution Controls provided a cost-effective, portable, and efficient solution for controlling welding fumes from dual operations. The result was a cleaner and safer work environment with long-term benefits for both productivity and compliance.

Improving Air Quality in Automated Welding Applications

Powertech Pollution Controls recently implemented a clean air solution for Hyundai Construction Equipment. The requirement was to manage welding fumes generated from an automated welding process on the shop floor. The goal was to improve air quality without interrupting the production flow for which our team provided a solution tailored to meet these needs.

The Challenge: Welding Fumes in a Production Environment

Automated welding operations generate fine fumes that can affect both workers and machinery. These fumes, when not controlled, lower air quality, settle on equipment, and pose health risks. In Hyundai’s case, the need was to have a welding fume extractor to capture these fumes close to the source without obstructing the automated process or limiting access to the workstation.

The Solution: Portable Welding Fume Extractor with Flexible Extractor Arm

To address the problem, Powertech supplied the FumeKiller® model FK3600VEM, a portable fume extractor. This model is designed to move easily across shop floors and deliver strong suction performance. The unit was fitted with a flexible extractor arm, which allows precise positioning of the suction hood. The arm ensures that the fume collection happens right at the source while allowing enough clearance for equipment and process movements.

Why This System Was Chosen

The FK3600VEM was selected for two key reasons. First, its portability made it easy to reposition based on the layout of the automated welding system. Second, the fume extractor arm allowed operators to move the hood close to the fume source without affecting the welding robot or setup. This ensured that the supplied fume extractor was practical, efficient, and non-intrusive.

The Outcome: Cleaner Air and Safer Operations

After installation, Hyundai reported a noticeable improvement in air quality around the welding station. The welding fume extractor captured the fumes effectively, keeping the workspace cleaner and safer. The portable setup also allowed the same unit to be used across different zones when needed, improving overall plant flexibility.

Conclusion

Powertech Pollution Controls delivered a targeted fume extraction solution for Hyundai Construction Equipment by installing a portable FumeKiller model FK3600VEM, with a flexible extractor arm. This setup offered effective fume capture, process compatibility, and ease of movement. As a result, the client achieved better air quality and a safer work environment without interrupting the automation process. This project shows how a well-matched fume extraction system can make a clear difference in real-world industrial settings. For any enquiries to do with a fume extraction system, get in touch with us today.

Choosing the Right Filter for Cleaner Air

Industrial processes like welding, soldering or machining all require efficient fume control
and fume extractors play an important role in maintaining safe air quality. The filters inside a
fume extractor is what traps the airborne pollutants before releasing the air into the
atmosphere or back in to the shopfloor. Generally, these systems make use of either HEPA
filters or Electrostatic filters. It is important to understand the working, advantages and
drawbacks of both type of filters to ensure that you choose the right system for your facility.

What Are HEPA Filters?

HEPA stands for High Efficiency Particulate Air. These filters are made of tightly packed fibers that trap very fine particles as air passes through. They are widely known for their ability to remove up to 99.97% of particles as small as 0.3 microns.

Strengths of HEPA Filters

• Highly effective at capturing small particles such as smoke, dust, and fine mist.
• Preferred in environments that demand strict air cleanliness, such as labs and electronics assembly.
• Easy to replace and commonly available.
• Has a comparatively lower cost for the same airflow capacity.

Limitations of HEPA Filters

• Require regular replacement, which adds to running costs.
• Can restrict airflow if clogged or overloaded.
• Higher pressure drop in the airflow leads to higher power consumption.
• Not washable or reusable.

What Are Electrostatic Filters?

Electrostatic filters use electric charges to attract and trap particles. As air flows through the unit, particles are given a charge and then captured by oppositely charged collector plates. These filters are common in welding fume extractors and soldering fume extractors. They also find use in oil mist collectors from neat cutting oil in CNC machining processes.

Strengths of Electrostatic Filters

• Excellent for capturing oil mist, smoke, and fine fumes.
• Can capture particles up to 0.01 microns in size.
• Filters are washable and reusable, lowering long-term costs.
• Maintain steady airflow since they do not clog like fiber filters.

The parallel plate design ensures lower pressure drop which leads to about 30 – 40% lower power consumption.

Limitations of Electrostatic Filters

• Require regular cleaning to maintain performance.
• May not trap larger particles that are typically caught in HEPA filters.
• Not suitable for dry, fibrous dust in some settings.
• Involves a higher initial cost for a system of the same air flow capacity.
  

What Type of Filter Should You Use?

The choice between HEPA and electrostatic filters depends on the type of air pollution in your facility. For very fine dry particles, HEPA filters are ideal. If your process produces oil mist, smoke, or sticky fumes, electrostatic filters offer better performance and lower maintenance.

Quick Comparison between HEPA and Electrostatic Filters

Conclusion

Both HEPA and electrostatic filters serve an important role in fume extraction systems. HEPA filters are best for high-purity environments where removing fine dust is the priority. Electrostatic filters work better in tough industrial settings with mist and smoke. Choosing the right one depends on the pollutants in your workspace and how often you can maintain the system. A well-matched filter will keep your air clean, reduce health risks, and protect your equipment.