Camfil Air Pollution Control partnered with a major auto parts manufacturer that used dust collectors to ensure clean air in robotic welding cells. The collaboration led to a significant reduction in downtime for maintenance of the dust collection systems.
The facility operators initially believed they had the best system available, as the previous vendor provided detailed computational fluid dynamics (CFD) data showing airflow performance. Their goal was to prove that the system was designed to prevent fires. However, reality didn't match expectations. The installed dust collection systems caused frequent downtime, high maintenance costs, and even fires within the collectors themselves.
Fire, Filter, and Fan Frustrations
The company faced recurring issues with its dust collectors, which led to substantial production delays. When the dust collectors caught fire multiple times, entire production lines were shut down for days. Additionally, when differential pressure built up, the fans would activate, making it impossible to perform pulse cleaning on the filters. As a result, staff had to manually clean the filters during lunch and break times, leading to at least two hours of daily downtime. Moreover, the filters needed replacement every six months, increasing both time and operational costs.
The noise from the fan systems also became an issue, causing complaints from nearby residents. The fans inside the collectors were prone to overheating, requiring the expensive replacement of several 50-horsepower motors annually. Accessing the fans for maintenance was especially challenging during winter, as the collectors were located outdoors, adding to the difficulty of routine upkeep.
Welding Dust and Fume Experts
Facility managers realized they needed a more reliable dust collector partner to ensure continuous operation of their manufacturing lines. Camfil APC’s Wayne Zimmer responded by bringing a Gold Series dust collector demo trailer to the site, showcasing the ease of maintenance and filter removal.
Eventually, Camfil APC introduced a new Gold Series dust collector system with a completely redesigned ductwork layout for the weld cells. This system allows facility operators to safely recirculate filtered air back into the plant using integrated safety monitoring filters.
Thanks to the improved efficiency of the new system, the manufacturer hasn’t needed to purchase new filters for over three years. There have also been no fires in the collector or additional maintenance required for the fans or electrical system. Impressed by these results, the company decided to install two more dust collection systems from Camfil APC.
Watch the Full Switching Story
To learn more about how this transition helped reduce downtime and improve air quality, watch Zimmer in this video titled “Preventing Downtime for Filter Cleaning.â€
Dangerous Airborne Particles in Welding Operations
Welding and cutting processes—whether manual or automated—emit harmful fumes, which are tiny airborne particles that can contaminate workshop air and pose serious health and safety risks to workers. Activities like arc gouging, plasma cutting, and laser cutting produce these fumes, and the amount increases with higher production levels.
The most effective way to minimize exposure to hazardous metalworking fumes is through well-designed dust collection systems equipped with high-efficiency primary cartridge-style filters. In some cases, secondary safety filters may be necessary to capture specific particulates.
Important Safety and Health Regulations
As seen after installing customized Camfil APC systems at this auto parts manufacturing facility, welding operations often recirculate cleaned air back into the workspace. However, the returned air must stay below OSHA permissible exposure limits (PELs) for metal contaminants generated during welding. Facilities that exhaust air outdoors must also meet EPA emission requirements.
OSHA PELs are based on an eight-hour time-weighted average (TWA) for metals found in welding fumes. These standards determine the minimum filtration efficiency required for dust collectors. Even if the air meets PELs, some workers may still face health risks, so further reductions in exposure may be necessary to ensure safe indoor air quality.
The EPA’s National Emission Standards for Hazardous Air Pollutants (NESHAP) Rule 6X regulates facilities that vent contaminated air directly outdoors. This rule covers hazardous air pollutants from metal finishing, including cadmium, chromium, lead, nickel, and manganese.
Cartridge filtration is recognized in Rule 6X as an acceptable control device to eliminate visible emissions. Installing dust and fume collectors with high-efficiency cartridge filtration systems, such as Camfil APC’s Gold Series industrial dust collectors, helps welding facilities maintain EPA compliance.
Click here to discover more solutions for controlling airborne particles in welding operations.
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