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Accelerating Efficiency: How an Auto Parts Manufacturer Cut Downtime for Dust Collector Maintenance
Collaborating with a prominent auto parts manufacturer, Camfil Air Pollution Control worked alongside their team to enhance the air quality in robotic welding cells through advanced dust collection systems. Initially, the client believed they had the best solution due to the complex computational fluid dynamics data presented by the previous vendor, which focused on airflow performance to prevent potential fires. However, the reality proved otherwise, as the existing systems resulted in frequent downtime, expensive maintenance, and even internal fires.
The company encountered numerous challenges with its current dust collectors. Frequent fires led to prolonged shutdowns of production lines, halting operations for several days. When the differential pressure inside the collectors rose, the fans would activate, preventing the pulse cleaning of filters. As a result, employees had to manually clean the filters during breaks, contributing to at least two hours of daily downtime. Additionally, the filters required replacement every six months, further increasing operational costs. The excessive noise from the fans caused complaints from nearby residents, while the fans themselves were prone to overheating, requiring costly motor replacements annually. Accessing the fans for maintenance was particularly challenging during winter, as the collectors were situated outdoors.
Realizing the urgency of finding a dependable dust collector partner, the facility managers reached out to Camfil APC. Wayne Zimmer from Camfil APC brought a Gold Series dust collector demo trailer to the site, showcasing the user-friendly maintenance and filter removal features. After thorough evaluation, Camfil APC installed a new Gold Series dust collector system tailored specifically for the welding cells. This innovative system allowed for the safe recirculation of filtered air back into the plant via integrated safety monitoring filters.
Since implementing the new system, the manufacturer has not needed to purchase new filters for over three years. There have been no incidents of fires in the collectors, nor any additional maintenance required for the fans or electrical components. Impressed by these results, the company decided to install two more dust collection systems from Camfil APC.
To learn more about the complete transformation, watch Zimmer's Preventing Downtime for Filter Cleaning video.
Welding and cutting activities, whether manual or automated, generate harmful fumes consisting of microscopic airborne particles that contaminate the workshop air and pose serious health risks to workers. Processes such as arc gouging, plasma cutting, and laser cutting produce these fumes, with the concentration rising proportionally with production levels.
The most effective way to reduce exposure to hazardous metalworking fumes is by installing well-designed dust collection systems equipped with high-efficiency primary cartridge-style filters. In certain scenarios, secondary safety filters may be necessary to capture specific particulates.
Regulations such as those set by OSHA and the EPA play a critical role in ensuring workplace safety and environmental compliance. For instance, after installing customized Camfil APC systems, this auto parts manufacturing facility can often recirculate cleaned air back into the workspace, provided it remains under OSHA permissible exposure limit (PEL) thresholds for metal contaminants produced during welding. If the air is exhausted outdoors, the facility must adhere to EPA emission standards.
OSHA PELs are based on an eight-hour time-weighted average (TWA) for metals found in welding fumes, dictating the minimum filtration efficiency required for dust collectors. Even if the air meets PELs in a facility, some workers might still experience health issues due to fumes. In such cases, reducing exposure limits further ensures safe indoor air quality.
The EPA’s National Emission Standards for Hazardous Air Pollutants (NESHAP) Rule 6X governs facilities venting contaminated air directly outdoors. This standard covers hazardous air pollutants from metal finishing, including cadmium, chromium, lead, nickel, and manganese. Cartridge filtration is acknowledged 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 the Camfil APC Gold Series industrial dust collectors, helps welding facilities remain compliant with EPA regulations.
For more insights into mitigating airborne particles in welding operations, click here to explore additional solutions.