Mist Collector

Harmful Effects of Water-based Coolant Mist

Water-based coolants, commonly used in various industrial processes and machining operations, is favored for its ability to cool and lubricate machinery effectively. However, while it offers numerous benefits, water-based coolant can also have harmful effects on both human health and the environment. This article details the properties of water-based coolants, their applications, and the potential adverse impacts they can have.

What are water-based coolants?

Water-based coolants, also known as cutting fluids or metalworking fluids, are liquids used in manufacturing and metalworking processes to reduce friction and heat generated during various processes like machining, grinding, and cutting. They typically consist of a mixture of water and various additives, including lubricants, rust inhibitors, and surfactants. These additives enhance the coolant’s performance and longevity.

Applications of Water-Based Coolants:

Water-based coolants find widespread use in various industrial applications, including:

  1. Metal Cutting and Machining: Water-based coolants are crucial in metalworking operations such as milling, turning, and drilling. They help maintain the tool’s temperature, prolong tool life, and improve surface finish.
  2. Grinding: In precision grinding processes, water-based coolants prevent jobs from overheating, reduce grinding wheel wear, and aid in achieving precise tolerances.
  3. Heat Treatment: Water-based quenching fluids are used in heat treatment processes to control the cooling rate of metal parts, preventing distortion and achieving desired material properties.

Harmful Effects of Water-Based Coolants:

Despite having their advantages, water-based coolants can have several harmful effects on humans as well as the environment and machineries:

1. Health Risks:

  • Respiratory Issues: Inhalation of airborne coolant mist, which contains tiny droplets of the coolant, can lead to respiratory problems such as coughing, shortness of breath, and even lung diseases.
  • Skin Irritation: Direct skin contact with water-based coolants can cause skin irritation, dermatitis, and allergic reactions. Some coolants may contain additives that exacerbate these issues.
  • Occupational Diseases: Prolonged exposure to water-based coolant mist may lead to occupational diseases, including occupational asthma and hypersensitivity pneumonitis, which can be debilitating and affect a worker’s quality of life.

2. Environmental Impact:

  • Contamination: Improper disposal of water-based coolant can result in soil and water contamination, negatively impacting ecosystems and potentially affecting drinking water sources.
  • Bioaccumulation: Some components of water-based coolants may bioaccumulate in aquatic organisms, entering the food chain and posing risks to human and environmental health.

3. Corrosion and Maintenance:

  • Corrosion: Water-based coolants can promote corrosion in metal components, particularly if not adequately managed or if the coolant becomes contaminated.
  • Maintenance Challenges: Keeping coolant systems and equipment properly maintained can be time-consuming and costly, and neglecting maintenance can lead to operational inefficiencies and increased risks.

4. Microbial Growth:

Water-based coolants are susceptible to microbial growth, leading to issues such as unpleasant odors, degradation of coolant properties, and potential health hazards for workers exposed to contaminated coolant.

5. Waste Generation:

Disposing of used coolant can be a challenge, as it may be considered hazardous waste due to its potential to contain harmful additives and contaminants.

Mitigating the Harmful Effects:

To mitigate the harmful effects of water-based coolants, several measures can be taken:

  1. Effective Ventilation: Implementing proper ventilation systems like mist collectors in industrial settings can help reduce the concentration of airborne coolant mist, safeguarding workers’ respiratory health.
  2. Personal Protective Equipment (PPE): Workers should wear appropriate PPE, including gloves, goggles, and respiratory protection, to minimize skin contact and inhalation of mist.
  3. Safe Handling and Disposal: Follow proper procedures for handling, storing, and disposing of water-based coolant to prevent environmental contamination and reduce waste generation.
  4. Regular Maintenance: Routine maintenance of coolant systems and equipment is crucial to prevent issues like corrosion, microbial contamination, and degradation of coolant properties.
  5. Alternative Coolants: Consider using alternative cutting fluids, such as synthetic or semi-synthetic coolants, which may have fewer health and environmental impacts compared to traditional water-based coolants.

In conclusion, while water-based coolants are indispensable in various industrial processes, their use is not without risks. Understanding the potential harmful effects of these coolants is essential for adopting appropriate safety measures and practices to protect the health of workers and minimize environmental impact. Proactive management and responsible handling of water-based coolants can help strike a balance between their benefits and potential drawbacks, creating a safer and more sustainable working environment.

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Oil Mist Collectors

An oil mist collector is a vital piece of industrial equipment designed to capture and remove airborne oil mist, smoke, and other fine particulate matter generated during various machining and manufacturing processes. This innovative technology plays a crucial role in maintaining a safe and clean working environment, ensuring worker health and safety, and improving overall industrial efficiency. In this article, we’ll dwell on the key aspects and significance of oil mist collectors.

Source and Generation of Oil Mist:

Oil mist is produced in a variety of industrial processes such as machining, metalworking, and tooling. These processes involve the use of cutting fluids, coolants, or lubricants to reduce friction, dissipate heat, and extend the life of cutting tools. As these fluids come into contact with high-speed machining operations, they can atomize into tiny droplets, forming oil mist. This mist contains both oil particles and other contaminants, including fine metal dust, which can be harmful to workers’ health and safety.

Health and Safety Concerns:

Exposure to oil mist and its associated particulate matter can have severe health consequences for workers. Inhalation of oil mist can lead to respiratory issues, eye and skin irritation, and long-term health problems, including occupational asthma and lung diseases. Moreover, oil mist can accumulate on machinery, floors, and surfaces, creating slippery conditions that can lead to accidents and workplace injuries.

The Role of Oil Mist Collectors:

Oil mist collectors are specifically designed to address these concerns by effectively capturing and removing oil mist and airborne particulates from the workplace air. They employ various techniques, including mechanical filtration, centrifugal force, and electrostatic precipitation, to achieve this goal. Here’s how they work:

  • Mechanical Filtration: Many Oil mist collectors use a series of filters, often including pre-filters and main filters. The pre-filters capture larger particulate matter, while the main filters are designed to capture the smaller oil mist droplets. These filters can be made of various materials, such as fiberglass, polyester, or HEPA (High-Efficiency Particulate Air), depending on the specific application.
  • Centrifugal Force: Some mist collectors utilize centrifugal force to separate oil mist from the air stream. The mist-laden air is directed into a rotating drum or chamber, where centrifugal force causes the oil droplets to be collected for disposal.
  • Electrostatic Precipitation: In electrostatic Oil mist collectors, an electric charge is applied to the oil mist particles, causing them to be attracted to oppositely charged plates or electrodes. This technology is efficient in capturing both fine oil mist and particulate matter as these provide a higher capture efficiency proving to be a better choice for industries.

Benefits and Significance:

Oil mist collectors offer a range of benefits and are highly significant in industrial settings for several reasons:

  • Worker Health and Safety: By removing oil mist and airborne contaminants from the workplace air, these collectors help protect the health and safety of employees. This is particularly important in industries where workers are exposed to oil mist on a daily basis.
  • Environmental Compliance: Many regions have strict environmental regulations regarding the emission of oil mist and particulate matter. Oil mist collectors help industries comply with these regulations and avoid fines or penalties.
  • Machine Maintenance: Accumulated oil mist can damage machinery and lead to decreased equipment lifespan. Oil mist collectors help prevent this by reducing the presence of mist in the workspace.
  • Improved Product Quality: In industries such as metalworking and electronics manufacturing, oil mist can settle on sensitive components and affect product quality. Collectors help maintain clean production environments and ensure product consistency.
  • Energy Savings: Some oil mist collectors incorporate energy-efficient designs, such as variable-speed fans, which reduce power consumption, contributing to cost savings and environmental sustainability.

Diverse Applications:

Oil mist collectors find applications in a wide range of industries, including automotive manufacturing, aerospace, machining, and metalworking, where the generation of oil mist is common. They are used in machining centers, CNC machines, grinding operations, and other equipment to ensure a cleaner, safer working environment.

In conclusion, oil mist collectors are indispensable tools in modern industrial settings, where the control of airborne oil mist and particulate matter is crucial for worker health, environmental compliance, and efficient manufacturing processes. These devices play a significant role in mitigating health and safety risks, preserving machine integrity, and improving overall industrial productivity. As industries continue to evolve, the importance of oil mist collectors in maintaining clean and safe workspaces remains paramount.

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mist killer

Different Types of Mist Collectors and Their Applications

In industrial settings where machining, grinding, or cutting operations occur, the generation of mist and aerosol contaminants is common. These airborne particles can pose health risks to workers and lead to declining air quality within the facility. Mist collectors are specialized devices designed to remove mist, aerosols, and other fine particles from the air, ensuring a cleaner and safer working environment. This article provides an overview of the different types of mist collectors available and their specific applications.

Centrifugal Mist Collectors
Centrifugal mist collectors, also known as inertial separators, utilize the principles of centrifugal force to separate mist particles from the air. This type of mist collector is commonly employed in various industries due to its efficiency and versatility.

1. Principle of Operation:

Centrifugal mist collectors direct the contaminated air through a series of baffles or vanes. As the air enters the mist collector, the centrifugal force causes the mist particles to move toward the outer walls of the collector. The separated mist drains into a collection reservoir, while the cleaned air is discharged back into the environment.

2. Applications:

Centrifugal mist collectors effectively remove coolant mist, and other water-based mists. They are commonly used in metalworking operations, such as machining centers, grinding machines, and parts washers. Centrifugal mist collectors are also suitable for applications involving the production of fine powders and dust particles.

Electrostatic Precipitators
Electrostatic precipitators (ESPs) are mist collectors that employ an electrostatic charge to remove mist particles from the air. They are particularly effective in capturing submicron particles and are widely used in industries with stringent air quality requirements.

1. Principle of Operation:

Electrostatic precipitators use an ionization process to charge the mist particles as they pass through an ionization section. The charged particles are then attracted to oppositely charged collection plates or tubes, where they adhere and are subsequently removed from the air. The cleaned air is discharged back into the workspace.

2. Applications:

Electrostatic precipitators are suitable for oil mist, smoke, and fine particulate matter applications. They are commonly used in metalworking, chemical processing, and pharmaceutical manufacturing industries. ESPs are highly efficient in removing hazardous contaminants and maintaining a clean and safe working environment.

Key Points

Here are three key points to consider when choosing the right mist collector for your specific application:

1. Airflow and Filtration Efficiency:

Different mist collectors have varying airflow capacities and filtration efficiencies. It is important to assess the volume of mist generated in your facility and select a mist collector that can effectively handle the anticipated airflow while providing the desired level of filtration efficiency.

2. Maintenance and Serviceability:

Regular maintenance is crucial for the optimal performance of mist collectors. Consider the ease of maintenance and availability of replacement filters when selecting a mist collector. Additionally, ensure that the mist collector’s design allows easy access and cleaning to minimize downtime and maximize productivity.

3. Compatibility with Applications:

Different mist collectors are designed to handle specific mist types, aerosols, or particulate matter. Assess the nature of the contaminants in your application and choose a mist collector that is specifically suited to handle those contaminants effectively.


Mist collectors play a vital role in maintaining a clean and safe working environment by removing mist, aerosols, and fine particles generated during industrial processes. Understanding the different types of mist collectors available, such as centrifugal and electrostatic precipitators, is essential in choosing the right solution for your specific application.

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Protect Your Workplace with High-Quality Mist Collectors

Workers are exposed to various harmful substances and pollutants in any industrial or manufacturing environment, including mist and fumes. These substances can lead to serious health issues if not adequately controlled. It is where most collectors come in, as they are designed to remove mist and other airborne pollutants from the workplace, thus ensuring a safe and healthy work environment.

Powertech Pollution Controls is a leading manufacturer of high-quality mist collectors designed to capture mist and fumes from various industrial processes effectively. These mist collectors are equipped with advanced technology that ensures optimal performance, making them an ideal choice for businesses looking to protect their employees and comply with health and safety regulations.

This article will explore the importance of using high-quality mist collectors in the workplace and highlight the benefits of choosing Powertech Pollution Controls top-performing mist collectors. With the right equipment, businesses can ensure a safe and healthy work environment and protect their employees from the harmful effects of mist and other pollutants.

The Need for Mist Collectors

Mist is a common byproduct of many industrial processes, such as machining, welding, and metalworking. The mist is produced when the fluid used in these processes is atomized into tiny droplets, which can become airborne and pose a severe health hazard to workers. Mist exposure can lead to various health problems, including respiratory issues and skin irritation.

To protect workers from these hazards, regulatory agencies worldwide require employers to implement measures to control mist in the workplace. It includes mist collectors, which are designed to capture and filter out mist before it can be released into the air. By using high-quality mist collectors from Powertech Pollution Controls, employers can ensure a safer workplace for their employees and compliance with regulatory requirements.

Powertech India’s High-Quality Mist Collectors

Powertech Pollution Controls offers a range of high-quality mist collectors designed to remove mist particles from the air in industrial settings effectively. These mist collectors are equipped with advanced filtration systems that ensure high filtration efficiency and maximum worker protection. They are also built to withstand harsh operating conditions, making them durable and reliable for industrial workplaces. With features like easy maintenance and low operating costs, Powertech Pollution Controls mist collectors are an ideal choice for any workplace looking to improve air quality and protect its workers from the hazards of mist exposure.

Benefits of Using Powertech India’s Mist Collectors

When choosing a mist collector, there are several factors to consider:

  • It’s important to determine the airflow capacity required for your workplace, as this will affect the efficiency of the mist collector.
  • Filtration efficiency is also a key factor, as it determines the ability of the collector to remove mist particles from the air.
  • The maintenance and operating costs of the collector should also be considered, as this will impact the long-term affordability and sustainability of the mist collector.
  • By considering these factors, businesses can ensure they choose a mist collector that meets their needs and provides optimal protection for their employees and workplace.

Factors to Consider When Choosing a Mist Collector

When selecting a mist collector, there are several important factors to consider. One of the key factors is the airflow capacity, which determines the amount of mist the collector can effectively remove from the air. The filtration efficiency is also critical, as it impacts the quality of air in the workplace and employees’ health. Additionally, maintenance and operating costs should be evaluated to ensure the mist collector is cost-effective and easy to maintain. Overall, considering these factors can help ensure that the selected mist collector is effective, efficient, and meets the workplace’s specific needs.


In conclusion, investing in high-quality mist collectors is essential for protecting the health and safety of employees in industrial workplaces. Powertech Pollution Controls range of mist collectors offers reliable and efficient solutions for controlling mist and improving air quality. Don’t compromise on workplace safety – choose Powertech Pollution Controls mist collectors for your industrial needs. Explore their range today to find the perfect mist collector for your workplace.

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Mist Collector for water-based Pollutants

Oil mist is a combination of 90-95% water and the rest 5-10% soluble oil; and depending upon the type of oil-based fluid being used, the mist can contain a number of other additives as well. When left on its own, oil mist turns into an oily substance on equipment and products.

What causes oil mist?

Oil mist and fumes can be caused through vapourization of the cooling lubricant around quick rotating tools like milling, grinding, and turning; or the condensation of vapourized cooling lubricant on warm surfaces. Either way, all surfaces coated with cooling lubricants can prove to be a source of emission. The warmer the surface, the greater the risk of contamination, which means higher risk to the employees.

Why is oil mist dangerous?

Long-term or repeated exposure to oil mist proves to be harmful for health. Workers who are exposed to oil mist are at a risk of developing skin disorders, respiratory problems, occupational asthma, bronchitis, or any other such respiratory tract irritation or breathing difficulties.

Why is it important to control oil mist within the premises?

It is important for employers to evaluate the potential impact that the manufacturing operations and processes may have on the workplace environment, and the wellbeing and health of the employees. Removing oil mist is thus an important aspect of any workplace, as it provides cleanliness as well as eliminates safety hazards. Controlling oil mist not only contributes to employee health, but also provides a positive impact on the general working environment.

Mistkiller – The ideal solution

The best solution for oil mist control is installing an industrial oil mist filtration unit that utilizes industrial oil mist filters for oil mist collection. The Mistkiller from Powertech Pollution Controls Pvt. Ltd. is a trademarked oil mist collector that is designed and developed for the control of most types of mist generated by the use of water-based coolants or liquids. It is an air pollution control equipment that works primarily on the principle of high-speed centrifugal collection of liquids. A prefilter, consisting of a small chamber with aluminium flakes, provides the initial gross filtration of the mist. The built-in suction fan, driven by an induction motor, provides a powerful suction that sucks the mist in through the exhaust port of the generating equipment and the connecting PVC duct. The fan’s high speed generates a centrifugal force that throws the mist against the inner side of the equipment’s enclosure, which then condenses under pressure, the collected liquid flowing down through the PVC duct, and returning to the generating equipment for re-use. The outlet is provided with a foam or steel postfilter, which needs simple periodic washing with a high-pressure water jet.

This product requires least maintenance and running costs, as compared with other conventional mechanical filters. Moreover, it can be used with a wide variety of applications like CNC and non-CNC machines, cleaning chambers, spraying systems, and more. Order the Mistkiller oil mist collector, to contribute to a safer and healthier work environment. Along with the product, you’ll also receive excellent product support, thanks to the years of experience and expertise that our team has.