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.

Installing a fume extraction system within your shop floor can help to remove smoke, fumes and other fine airborne particles. However, like any machinery, a fume extractor can fail or break down completely if not maintained properly. Regular maintenance keeps the system functioning efficiently, reduces downtime and can help save money over time.

Importance of Regular Maintenance of a Fume Extractor:

Lack of maintenance can lead to multiple issues within a fume extraction system, including:

• Filter blockages that can cause the system to break down.
• Reduced filtration efficacy and efficiency, directly  leading to reduced air quality.
• Higher power usage and potential risk of damage to the motor or other parts of the system.

Key Fume Extractor Maintenance Activities:

A well maintained fume extractor can perform better and have a longer lifetime. Below are some of the key tasks in maintaining a fume extraction system.

• Regular inspection of filters
  • Check filters every 2 – 4 weeks, depending on the usage.
  • In case of electrostatic fume extraction systems, the filters are reusable and will need to be cleaned, as per the manufacturer’s instructions.
  • In case of disposable filters, ensure timely replacement of all the filters that are full or damaged.
• Regular Cleaning of Filter Plates – For electrostatic fume extractors
  • Remove and wash the plates with mild detergent.
  • In case of sticky fumes like paint fumes, stronger cleaning aids will be required to clean the filters.
  • Ensure they are completely dry before inserting them back into the system.
  • Avoid using any sharp tools that may damage the filter plates.
• Check all moving parts of the system
  • Checks should include parts like the fan, motor and any other moving parts that are used inside the filtration system.
  • Listen to the sounds of the machine to check for any anomalies.
  • Ensure that the motor is not overheating during the operation.
  • Ensure that any parts that may seem worn out or unstable are replaced well in advance. This can help to avoid complete system failure.
• Inspect the system’s control panel in addition to all ducts and hoses
  • Check for cracks, bends or loose connections.
  • Clean any grime on the control panel surface as well as the inside of the ducts or hoses in case there is a visible buildup.
  • Secure any loose fittings and connections and replace any parts that are damaged.
• Maintain a log book of all maintenance activities
  • Keep a record of cleaning and filter replacement dates.
  • Monitor and log any performance issues regularly.
  • Keep track of any repairs that are done on the system.

Conclusion:

Whether you are using a welding fume extractor, soldering fume extractor or any other type of fume extraction system, it is critical that the system is maintained well. By following a simple maintenance plan and ensuring regular cleaning and maintenance of the filters and other moving parts in the system, it is possible to significantly extend the life of any fume extraction system. For more information about fume extractors and their maintenance, you can visit our website or get in touch with us today.

Industries which are in the manufacturing sector, including automotive, aerospace, tooling, heavy and light engineering, typically make use of CNC machining for various processes. This is primarily because these systems allow for precise designs implemented accurately and consistently for multiple parts and tools. These systems, however, do have a downside – they generate excessive amounts of heat during the machining processes.

The application and drawbacks of coolants:

To counter the generated heat, either water-based or oil-based coolants are used in the machining procedures. This subsequently leads to generation of oil or coolant mist that can reduce the air quality within the shopfloor. Additionally the mist particles may settle into the small gaps and crevices in the machines and can cause complete system failures if left unchecked. The poor air quality can also lead to health issues among the workers within the shopfloor.

Why Air Pollution Control is Essential

Through the use of a proper air pollution control system, the workspace can be kept clean and safe. Some of the benefits include:

1. Protect Health of Workers: By clearing the air of pollutants, the workers are protected from contaminants and reduce health risks.
2. Keep Machines in Good Condition: As captured mist particles can no longer settle within the gaps of the machines, the equipment stays clean and runs better for longer.
3. Meet Environmental Regulations: Cleaner air means adhering to environmental rules.
4. Economical Benefits: The captured coolant mist can be recovered from the mist collector and then reused, allowing for long term economical benefits.

The Solution: Mist Collectors

Based on the type of coolant being used, different types of mist collectors may be used to control the generated mist. Water based coolant mist can be controlled using a centrifugal mist collector. Alternatively, oil based coolant mist can be controlled using an electrostatic oil mist collector.

These mist collectors make use of the concept of mist evacuation where the entire volume of air within the enclosed CNC machines are evacuated within a short span of time, usually 5 – 10 seconds. This ensures that by the time the operator opens the doors of the machine, all the air is evacuated and no mist escapes into the shopfloor.
The process of CNC machining can lead to generation of oil based or water based coolant mist. These pollutants can be controlled using a mist collector. For any requirements to do with mist extraction, reach out to us today.

Keeping the air clean is a vital part of the operations within an industrial workspace and when dealing with floating dust particles, dust collectors are a crucial part of this process. The wrong type of dust collector will not only compromise the efficiency of dust extraction but the maintenance and operating costs as well. With this in mind, there are various factors to be considered to ensure that the right type of dust extraction system is chosen.

1. Type of Dust: Knowing this can help avoid blockages and the need for frequent cleaning.
   • Fine dust, generated from processes like polishing or sanding, would generally require a high-efficiency filter like cartridge filters.
   • Coarse dust, from cutting or grinding processes, will require more heavy duty filters like bag filters, capable of capturing the larger dust particles.
   • Moist or sticky dust can cause problems like clogging of the filters and may require filters that are custom designed and make use of specialized material.

2. Volume of Air and Suction Power Required to Capture the Dust Particles:
   • The volume of air flow required is measured in CFM (Cubic Feet per Minute) or CMH (Cubic Metres per Hour). 
   • The required air flow volume will vary depending on the size of the work area as well as the distance of the suction hood from the dust generation point.
   • The required suction force is determined based on the capture velocity or velocity of air flow required to move the dust particles.
   • In case of fine dust it can be between 100 – 150 FPM (Feet per Minute).
   • In case of larger dust particles the velocity would need to be higher and is approximately 200 – 250 FPM.

3. Volume of Generated Dust: Higher volumes mean more frequent cleaning.
   • In case the volume of dust being generated is low or moderate, a regular dust collection system would suffice.
   • However, in case there is a very large volume of dust being generated, the cleaning of the filters will need to be much more frequent which may hinder operation times.
   • For such cases, it is recommended to use a self-cleaning dust collector. The DustBag® Reverse-Pulsed Jet (RPJ) is a good example of this type of dust collector.

4. Maintenance and Cleaning: Choose a dust collector that is easy to maintain.
   • The collected dust needs to be disposed of and filters cleaned regularly to maintain operational efficiency of the dust collector.
   • As mentioned earlier, pulsed jet dust collectors are examples of self cleaning dust collectors that can automate the filter cleaning process and reduce downtime.

5. Safety and Compliance: Maintain all regulatory standards.
   • Dust can be hazardous, especially in industries like food or metalworking.
   • Some dust types are also flammable and even explosive. An example of this would be magnesium dust.
   • Ensure that the dust collection system meets standards as per the pollution control laws. Additionally, check for additional safety standards like ATEX if there is a risk of explosion.

6. Noise and Running Costs: Specific requirements for your dust collector.
   • If noise is a concern in the shopfloor, ask about models with acoustic conditioning for quieter operation.
   • Running costs include factors like energy use, maintenance schedule and filter life and replacement costs.
   • All of the above factors should be considered carefully to avoid long term issues.