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Maintaining machinery and equipment is an important part of ensuring optimal functionality and safety across the manufacturing industry. A significant step in maintenance is in properly cleaning parts. There are two primary techniques used to clean parts – blow-off stations and part washers.

Blow-off stations employ compressed air to eliminate moisture and debris. Whereas, part washers utilize various cleaning solutions for thorough cleaning and sanitization. It is vital to understand the differences between these methods to make an informed decision about the appropriate cleaning technique for your application. 

This blog post will provide insights into the differences between blow-off stations and part washers, as well as important factors to consider when selecting the most suitable cleaning method for your needs.

Blow-off Stations

Blow-off stations are cleaning devices that use compressed air to clean parts by blowing away debris and moisture. These stations are used for cleaning various types of parts – everything from small electronic components to more massive machinery equipment parts. Blow-off stations are typically used in industries where precision cleaning is critical as is the case in the manufacturing industry.

There are two main types of blow-off stations – handheld and fixed. 

• Handheld blow-off stations are portable and allow the operator to direct compressed air to specific areas. 
• Fixed blow-off stations are installed in a permanent position and are suitable for cleaning larger parts or parts that require constant cleaning.

The main benefit of using blow-off stations is their quick cleaning time. This allows for increased productivity and reduced operational downtime. They are also relatively low-cost and require minimal maintenance. 

Part Washers

Part washers are cleaning devices that employ diverse cleaning solutions to remove contaminants and clean parts thoroughly. They are commonly used in industries where parts necessitate a complete cleaning and sanitization, such as food processing and medical device manufacturing.

Part washers come in several types, such as immersion washers, spray washers, and ultrasonic washers. Immersion washers fully submerge the parts in a cleaning solution, while spray washers use high-pressure jets of cleaning solution to clean the parts. Ultrasonic washers utilize high-frequency sound waves to agitate the cleaning solution and eradicate contaminants from parts.

The major advantage of part washers is their ability to remove adhered contaminants, ensuring comprehensive and efficient cleaning. Nevertheless, part washers can be expensive and require frequent maintenance to ensure optimal performance.

Industries that widely use part washers include medical device manufacturing, automotive manufacturing, and food processing, where cleanliness and sanitation are critical.

Blow-Off Stations: The Preferred Choice for the Manufacturing Industry

When it comes to cleaning parts in the manufacturing industry, both blow-off stations and part washers are viable options. However, blow-off stations are often the preferred choice due to their speed, efficiency, and cost-effectiveness compared to part washers.

One of the prime benefits of using blow-off stations in the manufacturing industry is their cost-effectiveness. Blow-off stations need minimal maintenance and have a low initial cost, making them a budget-friendly solution for many manufacturers. Besides, blow-off stations can be used to clean various types of parts and surfaces, making them versatile and adaptable to different manufacturing applications.

Another advantage of blow-off stations is their efficacy in removing debris and moisture. These stations can efficiently remove contaminants that may negatively impact the quality and functionality of parts. Using compressed air for cleaning is an environmentally-friendly option that eliminates the need for harsh chemicals, reducing waste and pollution.

Blow-off stations are an excellent cleaning solution for the manufacturing industry, given their cost-effectiveness, versatility, and quick cleaning capabilities. They are ideal for removing debris and moisture from parts, guaranteeing their longevity and dependability. Incorporating blow-off stations into your cleaning process can improve productivity and quality, regardless of the type of parts you manufacture.

Minimize Oil Mist Exposure, Boost Efficiency, and Cut Down on Maintenance Expenses with the Aeroex Technologies’ BlowBox 

The Aeroex BlowBox BB-400 is an innovative, dual downdraft blow off station designed to prevent hazardous, atomized metalworking fluids from contaminating the air in your work areas. Engineered with the manufacturing industry in mind, Its compact design makes it an ideal solution for those seeking an efficient and cost-effective cleaning system.

Using the BlowBox is straightforward – just place your parts on the tray, turn on the system, and use your air gun to blow off the parts. The system generates 400 cfm of airflow, which captures aerosolized mist and collects it internally before draining it into a container of your choice. The air is filtered with a high-efficiency 95% HEPA filter, ensuring that any potentially harmful particles are effectively removed.

The BlowBox is also equipped with a powerful 0.3 hp electric motorized impeller, providing you with airflow on demand when you need it. This feature ensures that you can clean your parts quickly and efficiently, reducing downtime and increasing productivity.

If you’re looking for a  state-of-the-art blow off station that helps you minimize oil mist exposure, improve efficiency, and save on maintenance costs, consider the BlowBox BB-400 today. 

Final Thoughts

In conclusion, proper cleaning of parts is crucial for optimal functionality and safety across the manufacturing industry. Blow-off stations and part washers are two common techniques used for cleaning parts. 

While both methods have their advantages and disadvantages, blow-off stations are often the preferred choice in the manufacturing industry due to their speed, efficiency, and cost-effectiveness.

Blow-off stations are ideal for cleaning various types of parts and surfaces, making them adaptable to different manufacturing applications. They are also budget-friendly, requiring minimal maintenance and having a low initial cost. Moreover, blow-off stations are environmentally-friendly since they use compressed air for cleaning, eliminating the need for harsh chemicals and reducing waste and pollution.

Part washers, on the other hand, are best suited for industries that necessitate a complete cleaning and sanitization of parts, such as medical device manufacturing, automotive manufacturing, and food processing.

Regardless of the cleaning method chosen, it is essential to consider the factors that best suit your needs to make an informed decision. Incorporating blow-off stations into your cleaning process can improve productivity and quality, ensuring the longevity and dependability of your parts.

Environmental regulations have become increasingly stringent in recent years as governments and regulatory bodies recognize the importance of protecting our planet’s natural resources and ensuring a more sustainable future. One area of focus in these regulations is air quality. Companies are now required to comply with regulations related to air pollution and other environmental factors, and failing to do so can result in significant consequences. 

One important aspect of compliance with these regulations is in employing the use of mist collectors. Mist collectors are devices used in industrial settings to remove mist and particulate matter from the air, improving air quality and helping companies meet environmental regulations. 

In this blog post, we will explore the role of mist collectors in compliance with environmental regulations.

The Importance of Complying with Environmental Regulations

Compliance with environmental regulations is important for protecting the planet and ensuring a sustainable future in the long term and preserving the health and safety of your workplace environment. These regulations are designed to limit pollution and other harmful practices that can have negative impacts on the environment and human health. 

Non-compliance can result in significant consequences for businesses, including fines, legal action, and damage to a company’s reputation. Complying with these regulations can lead to improved air quality, reduced waste and energy use, and a healthier work environment.

It is the responsibility of companies to prioritize compliance with environmental regulations, not only for the benefit of the planet but also for the long-term success of their business.

The Role of Mist Collectors in Environmental Compliance  

Mist collection systems play a critical role in helping companies comply with environmental regulations related to air pollution, as they can significantly reduce the number of harmful particles and chemicals released into the atmosphere. 

These systems are engineered to capture mist, smoke, and other airborne particulates that are generated during manufacturing processes in a variety of industries, including metalworking, woodworking, and food processing.

This is important because many of these pollutants, such as oil and coolant mist, can have serious health and environmental impacts. When inhaled, oil mist can cause respiratory problems and other health issues. 

Mist collectors work by using a series of filters and centrifugal force to separate the mist from the air. By capturing these pollutants before they are released into the air, mist collectors help to ensure that industries meet the strict environmental regulations set by regulatory bodies.

Mist collection systems also offer economic benefits for industries. By reducing the number of pollutants released into the environment, industries can avoid costly fines and penalties associated with non-compliance with environmental regulations. Mist collectors can help to improve the overall efficiency of manufacturing processes by improving air quality for workers. While regulatory compliance is important, environmental considerations can also enhance your public reputation as a demonstration of company values and attract investors seeking environmentally responsible businesses.

Environmental Regulations Related to Air Pollution

Canada Regulations

Each province and territory in Canada has its environmental regulations related to air pollution, in addition to federal regulations. These regulations may be more stringent than federal regulations. Companies that use mist collectors must be aware of any provincial or territorial regulations that apply to their operations.

The Canadian Environmental Protection Act (CEPA) is a federal law that regulates substances that may have an impact on human health and the environment. The law authorizes the regulation of emissions of toxic substances into the environment, including indoor air quality. Companies that use mist collectors may be subject to CEPA regulations, depending on the type of pollutants they generate.

The National Pollutant Release Inventory (NPRI) is Canada’s national inventory of pollutant releases and transfers. The inventory requires companies to report on their releases and transfers of over 300 substances, including air pollutants. Companies that use mist collectors may be required to report their emissions of pollutants such as volatile organic compounds (VOCs) and particulate matter.

Industrial Emission Performance Standards (EPS) are performance standards that have been established for various industrial sectors in Canada. The standards set emission limits for air pollutants based on the type of facility and the production process used. Companies that use mist collectors must comply with the EPS for their sector.

Environmental standards are regulated both federally and provincially. Each province will have further provincial regulations it must comply with – for example, the province of Ontario has regulations including the Environmental Protection Act and the Clean Water Act. These regulations will complement those at the federal level, typically prescribing with greater detail in areas of provincial jurisdiction. 

USA Regulations 

One of the most significant environmental regulations related to air pollution is the Clean Air Act (CAA). This federal law regulates air emissions from stationary and mobile sources. The Environmental Protection Agency (EPA) has the authority to establish national ambient air quality standards and regulate emissions of hazardous air pollutants. Companies in industries like manufacturing, metalworking, and woodworking may be subject to a range of CAA regulations, depending on the type of pollutants they generate and the size of their operation.

Another set of EPA regulations is the National Emission Standards for Hazardous Air Pollutants (NESHAP). It establishes emission standards for specific hazardous air pollutants. 

Companies that are installing new mist collectors or upgrading existing ones may need to comply with the New Source Performance Standards (NSPS). These are EPA regulations that establish emission standards for new or modified stationary sources of air pollutants.

In addition to federal regulations, many states and localities have regulations related to air pollution. Companies that use mist collectors must be aware of any state or local regulations that apply to their operations.

How Mist Collectors from Aeroex Technologies Can Help

Overall, environmental regulations have highlighted the importance of technologies like mist collectors in reducing the environmental impact of industrial manufacturing. As these regulations continue to evolve and become more stringent, it is likely that the use of mist collectors and other air quality control technologies will become even more widespread as industries strive to meet these regulations and protect the environment.

Luckily, Aeroex Technologies is a manufacturer of mist collectors that can help companies comply with environmental regulations related to air pollution. Aeroex mist collectors are designed to capture mist and other airborne particulate matter generated by industrial processes. This helps to reduce emissions of hazardous air pollutants and meet regulatory requirements for air quality. 

Additional benefits of choosing Aeroex Technologies’ mist collection systems include:

• Energy Efficiency: Aeroex mist collectors are designed to be energy-efficient, helping companies to meet regulatory requirements for energy consumption.
• Easy Installation and Maintenance: Aeroex mist collectors are easy to install and maintain, which can help companies meet regulatory requirements for equipment installation and upkeep.
• Customized Solutions: Aeroex Technologies can provide customized mist collection solutions to meet the unique needs of different industries and applications. This can help companies comply with specific regulatory requirements and avoid legal penalties.

If you’re looking for a highly efficient mist collection system that complies with environmental regulations and standards, get in touch with Aeroex Technologies today.

Location of Mist Collectors

The design, filtration size, and air handling capacity of industrial filtration systems like oil and coolant mist collectors are often discussed for their impacts on air quality. However, the location of the oil mist collector is an overlooked but critical aspect of your air filtration strategy. The location of the mist collector is a key consideration for any deployment made by Aeroex. By ensuring the proper placement and integration of the mist collector, the right capture strategy can be used that provides optimal efficiency. 

Types of Locations for Mist Collectors

There are two general ways of locating your coolant and mist collector. You directly integrate the filtration system with your machine to provide source control as a closed system, or you can install it nearby on the wall or ceiling (often paired with your existing ventilation) to provide ambient control. Each provides benefits and rationale, although for machining operations Aeroex recommends starting with source control first. 

Location of Mist Collectors for Source Control

Source control means capturing contaminant air particles directly at the source of release by maintaining close proximity and a direct feed between the source and the method of filtration. The advantage of this technique is that the duration between release and capture is limited, there are fewer opportunities to enter the atmosphere, and a higher concentration of particles can be captured before they begin to diffuse. A source control solution is highly efficient as a result – a higher concentration means less air is circulated through the filter for the same amount of particles captured. However, a source control solution can be more demanding for the air filtration system. If it cannot efficiently remove the large number of particles, you may get a buildup or disruptions like clogging. 

Aeroex systems are designed for source control locations first and foremost, with depth loading filters, screening methods to optimize filter efficiency, good drainage, and large volumes of filter media. This is the most efficient way to target oil and collant mists that come from a discrete source. In machine shops, oils and coolants are usually sprayed within an enclosure, making them opportune for a source control strategy. 

Location of Mist Collectors for Ambient Control

If an ambient control strategy is being used, typically the filtration system will be installed on the ceiling or with an existing ventilation system to oversee a broader area or a series of operations and sources. Normally, an ambient strategy is only recommended when a contaminant source is not discrete or there are too many sources for a source control strategy to be feasible. Some machine operations like grinding also pose source control challenges. Ambient control can also complement source control – for example, if you had several grinders equipped with source control measures you may also use ambient control as the finishing method to eliminate any remaining contaminants.  

An ambient control solution applies to the entire room of a facility, meaning it will need to circulate more air than a source control method to replace contaminants with clean air. This is due to the effects of dispersion. As well, the lower circulation frequency compared to source control (enclosures can often be cycled in seconds) mean that there is the potential for interim exposure in the atmosphere. 

While source control is most common for machine operations, ambient control is common in other applications like healthcare and institutional settings.

Mounting Oil Mist Collector for Source Control Strategy

Aeroex is committed to the source control strategy, so much so that we have created a wide range of mounting options to ensure that whatever the circumstance, models like our Mist Fit can integrate into your shop. Where other suppliers may opt for a less efficient strategy due to accessibility issues, we will go to extra lengths to ensure a source control strategy is feasible. We understand space is a scarce commodity in any machine shop, and mounting to a machine can therefore require some creativity. Our install kit provides mounting options by including custom and prefabricated base plates, flanges, base plates with side suction, side mounts, elevated base plates, side mount extensions, pillar stands, wall mounts, and more.

How to Choose the Location of Mist Collectors

When choosing the location of your mist collector, we will assess the footprint of your facility, the existing ventilation, the location of your machines, conflicts with other devices and utilities, routing, accessibility, and other factors. From there, we will assess the options for a source control strategy. Often this is straightforward but if not the Aeroex team will get creative in providing you with a safe and optimal location solution. In almost all cases, source control is achieved.

Learn More in This Case Study of Determining the Location of a Mist Collector 

For an example of the installation process, check out Aeroex’s video feature in popular Youtuber and custom knife fabricator Grimsmo Knives. 

Grimsmo Knives is a Canadian business making custom knives. The process includes operations like lathing with common machine brands like Nakamura. In this video, we visit John Grimsmo’s shop and learn about the buildup of oil and coolant mist experienced in the shop when machines are in operation. Grimsmo Knives has a small shop with limited ventilation and there were initially some questions about how best to locate the oil mist collector, but over the course of the video viewers get to see the process for a full installation. The hosing in our installation kit made the process go by quite smoothly. By the end of our site visit, the Mist-Fit 550 was fully installed and providing immediately noticeable clean air. 

You can also learn more by reading our Grimsmo Knives case study.

Employing the use of a mist extraction system in tandem with regular CNC machining equipment operations can aid in preventing risks that you may not easily identify with the naked eye. Luckily, Aeroex Technologies engineered mist collection systems are built with the unique needs of CNC equipment processes in mind. Our mist collectors effectively remove mist from the workplace environment to ensure your machine operators and facility equipment are not exposed to health and operational risks down the line. 

In this blog we uncover the mist extraction needs unique to CNC machining and how Aeroex Technologies’ offers a reliable and efficient mist collection system tailor-made to meet these needs. 

The Important Role of CNC Machining Processes for Manufacturing 

CNC machining equipment plays a fundamental role in manufacturing for their ability to produce accurate and specific parts by turning raw materials into final products. CNC stands for Computer Numerical Control, which represents two standard methods (3D printing technology and FDM) to build prototypes all from a computer software file. CNC machining has been used to manufacture a range of materials including wood, metals, and plastics.

Unfortunately, a common byproduct of CNC machining is chip formation. Chip formation occurs when the machine tool makes contact with the edge of the material that is being worked on. Common with CNC machining processes such as milling, grinding, honing, and turning – chip formation is imminent. Chip formation can detriment the production process leading to shortened tool life, stoppages, lack-luster surface finishes, and can increase the likelihood of safety hazards from occurring. 

Many CNC machine operations will employ the use of a high-pressure coolant to deal with chip formation control. High-pressure coolants offer a myriad of benefits when it comes to controlling chip formation, but an unfortunate byproduct is that it leads to the dispersion of coolant mist into the air which can lead to slick work environments, and post significant health risks to facility personnel as well as to other equipment in your facility. 

It is for this reason that effectively controlling the dispersion of coolant mist is regulated by OSHA, NIOSH, ACHGI, and Health Canada. All of these governing bodies dictate legislation to limit exposure to harmful workplace pollutants like oil and coolant mist. 

Health Risks Associated with Coolant Mist Exposure 

Exposure to coolant mist and toxic fumes include irritation of the eyes, skin, mouth, and throat, and can lead to other symptoms like headache, shortness of breath, fever, rapid heart rate and vomiting. Persistent and unchecked long-term exposure to oil and coolant mist can increase the likelihood of developing more serious respiratory and skin diseases including cancer.

Despite the growing trend toward the regular use of high-pressure coolant for CNC machining applications, there has been a gap for a solution that effectively filters through the airborne particulate that high-pressure coolants disperse into the working environment. 

Aeroex Technologies’ Mist Extraction for CNC Machining Solution

Because CNC machining utilizes 3D printing technology, the team of experts at Aeroex Technologies have conducted extensive research to inform engineering efforts when it comes to addressing the types of mist and fumes emitted by 3D printing. Paying special attention to factors like composition and quantity, the Aeroex team understood the importance that source capture extraction systems play in the more modular processes in which 3D printing emits mist and fumes. 

Source capture filtration effectively and efficiently mitigates dispersion of harmful mists and fumes from being emitted into the working environment, as it is captured at the source. Ambient filtration in contrast, collects unwanted airborne particulates that have not been filtered immediately via source capture filtration. Depending on your facility needs, employing the use of both ambient and source capture filtration might be the best solution for you. We recommend reaching out to learn more about how Aeroex Technologies can propose a mist collection system that meets your unique facility needs. 

How the Mist-Fit Meets the Unique Filtration Needs for CNC Machining Processes

Aeroex’s line of Mist-Fit mist collection systems have been engineered to mitigate risk of oil and coolant mist exposure for CNC machining applications. Benefits of selecting the Mist-Fit for your facility include:

• Multiple stage filtration to ensure high efficiency and avoid plugging from occurring 
• Less maintenance and more cost effective due to longer filter life
• Option to select a 4th-stage HEPA filter to capture extra fine mist particulates 
• Compact, modular design and multiple direct mounting options make the Mist-Fit highly adaptive and easy to install
• Canadian-based and engineered to yield high-quality results and service

Aeroex Technologies’ team of engineers are able to assess your shop’s needs to offer a high-quality mist collection solution that is economical, highly efficient, and made with CNC machining equipment in mind. Our dedication to offering high-quality mist collector products is matched by our commitment to customer service. 

If you’re looking for a mist extraction solution for your facility, consider the Mist-Fit line of mist collectors and request a quote today!

Oil and coolant mist collectors are often defined by the smallest particle size they can filter, but calculated airflow is just as important. In fact, focusing on filtration size or failing to consider other factors like airflow may be leading to less than optimal performance. Filtration size might be the right starting point, but we’ll go over some of the reasons why you need to consider airflow when using oil and coolant mist collectors for industrial air filtration. 

What Is Air Flow and Why Is It Important for Industrial Air Filtration

In the context of industrial air filtration, airflow describes the nature and rate at which air is circulated and discharged using a mechanical ventilation system. This could be across a facility, within a particular production room, or in a machine enclosure. Airflow is measured using units of volume (e.g. cubic feet or meters) and time (e.g. minutes or seconds). Aeroex uses cubic feet per minute (or “cfm”) as its standard unit of measurement. Airflow also has a direction or vector, such as from areas of high to low pressure or from a source of forced air to a source of air capture. The direction, volume, and velocity of airflow all play important factors in the performance and outcomes of your filtration scheme. 

Airflow is important for industrial air filtration because it is a key determinant of the ability to capture or mitigate the effects of airborne contamination caused by industrial processes like machining. This can be true both at the macro level for a large facility or at the source of a single machine. Consider the following examples.

Example #1 – Air Flow Considerations for Source Control Applications 

You are machining at high cycles and use coolants or lubricants to maintain the temperature of your tools, but need to maintain visibility or prevent the over-accumulation of oils and mists. Therefore, your ventilation and oil mist collection system will need to recycle the enclosure every few seconds. By extension, your oil mist collector needs to have the airflow capacity to do so. The “direction” of airflow is of less concern here because it is a closed system with source control. Aeroex often recommends source control solutions because contaminants are captured quickly before they are released into the shop atmosphere where they disperse – you can often capture at the source with less airflow than what is required under ambient conditions. 

Example #2 – Air Flow Considerations for Ambient Control Solutions 

You may use an ambient control method for air filtration when source control is not feasible – for example, some grinding applications without enclosures may not achieve 100% success with source control. Ambient control is also used as a “finishing” method complementing source control to achieve the cleanest possible air. Here, you need to consider the entire volume of the room rather than just an enclosure, and you also need to consider the direction of airflow relative to your air filtration system. The placement of different sinks and sources of ventilation will determine the overall flow in a facility, and proper engineering is needed to ensure the entire room is circulated. If there are corners circulated less frequently or at limited capacity then there are areas of higher risk. Ambient control often requires high airflow because you will be recycling an entire room of air, usually several times per hour.

Engineering the airflow of a room or facility is a complex topic, and deploying an industrial air filtration system may mean consulting an engineer – Aeroex has experienced staff who can make sure any deployment is planned properly. The below figure depicts some examples of common airflow dynamics.

Figure – Types of Air Flow Dynamics for Planning Ambient Industrial Air Filtration (Source: Building Performance Institute) 

Risks of Inadequate or Mismatched Air Flow

Performance is often described in terms of the smallest size of particles captured by a filter, but if your oil mist collector cannot deliver the required airflow then the contaminants are not being removed at a rate that can ensure the quality or safety you expect. The filters selected can impinge on airflow, especially among cheaper membrane filters without the proper screening or depth loading to prevent clogging or deliver higher volumes of air. While filters may often guarantee using things like the HEPA standard, an improperly sized filter will negatively impact the air flow generated. Once airflow is restricted, contaminants will bypass the filter and carry into the airspace downstream of your filtration system – an outcome your filtration system was intended to prevent. For this reason, Aeroex uses depth-loading filters and provides a wide range of capacity options, ranging anywhere from hundreds of cubic feet per minute to thousands. 

While it’s common among other suppliers to be overpromised on a system with inadequate airflow, you also want to avoid overpaying for capacity you don’t need at additional cost. 

Why Is Filtration Size Mistakenly Emphasized Over Airflow?

Within the industrial air filtration space, we often speak in terms of particle size because it’s something all applications can relate to. Contaminant particle size, within a theoretical range, is common to all applications. While particle size can vary with temperature, dispersion method, etc, its chemical composition means that particle size will be within an accepted range. This means that the design and business case of a filtration system can relate to everyone via consideration of particle size. This commonality creates a shared language but can omit the factors that make each situation unique (notably your airflow requirements).

Airflow will depend on your enclosure size, amount of oils and coolants being applied, machine type and technique used, desired air exchange frequency, etc. At the ambient level, you will also need to consider the size and orientation of the facility, along with the other airflow contributors. 

Get The Right Airflow Advice

So, while filtration size can start the conversation, don’t make the mistake of not selecting your mist collector based on calculated airflow. At Aeroex, we will diligently and patiently understand all your needs including calculated airflow to recommend the right mist collector. If you want to learn more or get started, contact Aeroex today.