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Mist Collectors
Mist Collectors for Cold Heading
November 15, 2021

Mist Collectors for Cold Heading

Cold heading is preferred over metal cutting operations for this process due to its ability to generate less waste while producing large quantities. However, while more efficient – cold heading machines are not immune to the output of oil and smoke buildup. 

Learn how oil mist collectors aid in reducing exposure to smoke and oil mist in cold heading processes below.

How does Smoke and Oil Mist Occur in Cold Heading?

Cold heading, also known as cold forming, is the manufacturing process where metal wire is fabricated into fittings and fasteners without heat and at high speed. The amount of smoke and oil mist will depend on several factors – the type of metal used, the diameter of the stock, the speed, the specific process being performed, and the type of lubricant applied. 

Oil lubricants are used to prevent excess wear and tear of the dye in the cold heading process. When lubricants are used, heat becomes vapor – resulting in smoke and oil mist. Mist is generally defined as a liquid droplet that is or less than 20 microns in diameter. Smoke is much smaller in comparison as it can range from 0.07 to 1 micron in diameter, and can be either liquid or solid. 

Cold Heading Mist Collectors
Cold Heading Mist Collectors

Identifying Oil Mist Problems

Some believe that if they are unable to see the mist, it must not exist. This point of view fails to realize the issues that submicron mist can pose in the shop environment. Moreover, the presence of mist can be realized by the other senses. There is typically a distinguishing odor when oil mist is present. 

Depending on the lubricant used, the smoke and oil mist can also accumulate and become sticky to touch – adhering to the shop environment and the machines it houses. Regular cold heading operation without adequate industrial air filtration will eventually lead to the visibility of smoke and oil mist – on the floors, walls, lights, and equipment. 

The Risk of Long-Term Exposure to Smoke and Oil Mist

Simply put, conventional methods of managing air quality around cold heading machines do not effectively mitigate the risks associated with long-term exposure to smoke and oil mist. Using masks, mechanical vents with primary filters, and regular clean-up of the shop environment may be able to mitigate the impact of minimal exposure to smoke and oil mist. But they are unable to properly manage the air quality when it comes to long-term exposure to smoke and oil mist. 

Maintaining industrial air quality is essential when it comes to the health of shop personnel, your equipment performance, and ultimately – the success of your business. 

Slick or sticky shop environments and poor air quality due to smoke and oil mist can result in severe health issues for shop personnel. Slick environments can lead to more injuries related to slip and fall accidents. People that are exposed to oil mist can experience irritation of the eyes and skin, a burning sensation in the mouth and throat, as well as fever, rapid heart rate, shortness of breath, headache, and vomiting. More severe health issues related to long-term exposure to smoke and oil mist can also lead to skin and respiratory diseases, as well as cancer. 

Improper air filtration of smoke and oil mist will also deteriorate machine life over time- ultimately contributing to increased operational and maintenance costs. It is for these reasons that proper air filtration for cold heading is essential to ensuring the health and safety of shop personnel and equipment. 

Mist Collectors for Cold Heading Machines

Mist concentration in cold heading processes will differ in comparison to other machining processes. Cold heading processes create a high amount of oil smoke, and exclusively used electrostatic mist collectors up until 15 years ago. The primary issue with the use of electrostatic mist collectors is that they did not efficiently collect the oil in the smoke, as the oil is an insulator. This resulted in the electrostatic cells to decrease in efficiency, and led to increased cleanings of the electrostatic oil mist collector (as often as twice a week for heavy loading, and once a month on lighter loading). 

The primary purpose of an oil mist collector for cold heading machines is to remove smoke and oil mist droplets from entering the shop environment. However, certain mist properties will impact mist collector performance. 

OSHA states that the limit for airborne metalworking fluids (coolants) by 8-hour exposure, from 5 mg/m³ for mineral oil and 15 mg/m³ for other coolant types. NIOSH recommends lower at 0.4 mg/m³. 

Increased temperature can result in condensation – impacting droplet size and how it is collected. For instance, when water-based coolants are utilized – water will evaporate at higher temperatures and lower humidity – resulting in smaller droplet sizes. 

The type of mist will also impact mist collector performance. As different types of mist droplets will have varying surface tension and viscosity properties, this will affect the mist collector’s ability to collect and drain the fluid. Moreover, if a mist contains many dry particles (swarf) then they will also need to be removed in addition to the coalescing (collection) of the droplets. 

Aeroex Mist Collectors for Cold Heading Processes

Innovation in oil mist collector technology over the past 15 years has introduced a more efficient solution that requires less maintenance. Today, most cold heading operations have converted to mist collectors that use fibre beds to deal with smoke and oil mist. 

Canadian-based Aeroex Technologies’ line of Mist-Fit and ARO mist collectors are made with cold heading applications in mind. Aeroex’s mist collector solutions reduce consumables by utilizing mechanical progressive filtration, quality fibre bed technology, and HEPA filtration in tandem to provide superior smoke and oil mist collection performance that ensures clean air and reduced maintenance costs. In fact, maintenance is low with filter life spanning up to 3 years. 

The Aeroex team of engineers and specialists will evaluate your unique needs, and can recommend an industrial oil mist collector solution that will limit exposure to oil and coolant mist as the result of cold heading processes. Get in touch with a representative today and eliminate the negative effects of long-term exposure to smoke and oil mist on your shop personnel and equipment. 

Mist Collectors
Mist Collectors for Grinders
November 15, 2021

Mist Collectors for Grinders

Grinding is a great technique for finishing products by smoothing surfaces or other final steps like adding grooves. Given the number of goods that can be produced with flat surfaces, techniques like surface grinding are very common. Other examples of grinding techniques include centerless grinding (typically faster than surface grinding and requires fewer passes) or cylindrical grinding (for specific round product shapes). These different types of grinding have their advantages and use cases, but also have some common challenges. In contrast to most other machining operations, grinding generally does not use an enclosure unless the facility has a customized enclosure for grinding (however these enclosed grinders usually have very high demand oil applications, discussed further below as a case study). Open-air grinding leads to dirtier operations that release lots of byproducts like oil mist. The heat generated by the wearing surface can lead to friction, burning, or swarf accumulation which is why a mist collector for grinders is recommended.

Oil Mist from Grinding Wheels

The abrasive surface of the wheels used for grinding can come in a variety of materials, usually aluminum oxide, silicon carbide, diamond, or cubic boron nitride. These materials also vary in hardness, which will play a role in determining what the process quality is. However, some materials can cause the previously mentioned issues of heat generation. In some cases, the heat generated can also lead to loose material, lower production quality, and burn marks. Modern machine operations typically address this issue through oils that cool the cutting surface and provide lubrication. The use of oil will improve the process quality and the longevity of the tools but will produce mist and workplace issues that require the use of a mist collector for grinders. This issue is exacerbated by the open-air workspace of grinding. 

Typically, the type of oil used will depend on the material of the product. The Manufacturing Product Reference Guide typically recommends light or heavy-duty oils for common materials like aluminum, with the added recommendation of synthetic oils for materials like stainless steel and plastics. Each of these oils will have its considerations such as the particulate formation, current regulatory guidelines (OSHA at a minimum but not a best practice), and viscosity/density (typically, synthetic oils are the cleanest to work).

Mist Collector for Grinders
Aeroex Mist Collector for Grinders

Causes of Oil Mist During Grinding

A common refrain among oil mist collection for machining is “the faster the process, the finer the particles”. Oil mist is applied to promote speed and reduce heat generation, but this increased speed of machining (in this case grinding) causes subsequent problems. At typical speeds where oil mist becomes a practice, oil mist is producing sprays of droplets mechanically and vapors of oil thermally. As grinding speeds increase, the amount of heat vaporizing the oil will also increase. Vapors are much harder to deal with than droplets because they are significantly smaller in particle size, meaning there are more of them but they are smaller and harder to filter. The size and volume of these vaporized particles mean that an efficient mist collector for grinders is required. 

Risks of Oil Mist from Grinding

Oil mist can be contained within the machine enclosure immediately after application but left any longer and accumulation would cause films to develop in your equipment. If exhausted or the hood is lifted, the oil mist will be circulated or released into your shop floor. If you do not have an enclosure, then release is already an issue. Oil mist can create visibility issues from the misty haze, which then lands on your floor and creates slip hazards. While in the air, it can be breathed in by staff or create irritation in body parts like the eyes. If exposure persists, there will be health issues and possibly a workplace that contravenes regulatory requirements for health and safety.

How to Remove Oil Mist from Grinding

The answer to the challenges of a grinding process made efficient with oil coolants that cause dangerous mists? An oil mist collector for grinding that provides an efficient source control solution achieving sub-micron particle removal. The mist collector will need to capture the large droplets mechanically dispersed from the grinding process, as well as the smallest particles vaporized from the heat of faster grinding. It should be efficient, and powerful enough to provide the cycles desired in your shop.

For machining applications like surface grinding, cylindrical grinding, or centerless grinding, Aeroex typically prescribes the use of the Mist-Fit series of oil mist collectors for grinding. Aeroex takes a different approach to open-air grinders than other machine applications and includes configuration options that ensure the source control solution that captures all pollutant particles before they can be released into the shop (at which point elimination by ambient control is much harder to achieve).

The Mist-Fit mist collector for grinding delivers a series of separation processes that remove any oil mist with increasing efficiency in each stage. The primary mechanical and secondary demister capture up to 95% of oil mist, notably the mechanically generated particles that are larger. The next stage in the filtration series is a depth loading fiber bed with high media volume – this MERV 15 rated filter will capture up to 95% of the oil mist particles. This efficiency is often more than sufficient for standard applications, but our products also carry HEPA filters durable enough for long-lasting air purification for machining while providing the highest standards in removal efficiency (99.7% @ 0.3 µm). 

Case Studies in Mist Collectors for Grinding

We have seen that grinding as an open-air machining operation poses challenges to workplace safety and quality that can be effectively treated with Aeroex’s Misfit Solution. However, many grinding applications push the limits of current machining practices. Aeroex is at the forefront of these applications and is delivering mist collector solutions.

A customer specializing in biomedical manufacturing was using enclosed grinding centers with high-pressure oil. The demanding nature of the high-pressure oil meant the customer had gone through multiple competitor mist collectors before trying the ARO Series mist collector. The result was the client not seeing any oil leave the machine for the first time. Efficiency was the best they had seen, and they achieved longer filter life than competitor oil mist collectors. As a result, the ARO series deployment was expanded from a pilot station to all the machines in the biomedical manufacturing facility. 

Aeroex has seen similar client journeys with other grinding operations. A recent example includes an aerospace parts manufacturing facility. The specialized grinding equipment was enclosed and high-pressure oil was being applied. This aerospace manufacturer went through several competitor mist collectors before ultimately selecting the ARO Series mist collector.

Our mist collectors for grinding are made in Canada, provide the best value and lowest lifecycle cost (achieved through low filter maintenance frequency), and encompass design principles that reflect Aeroex’s leading knowledge of machining processes like grinding. This article provides a brief overview, contact Aeroex today for a specialist who will guide you through the strategy of selecting a solution that provides you your desired outcomes for the best value. 

Air Purification
November 12, 2021

Air Filtration System for Wood Shop

An overlooked hazard in any industrial woodshop is toxic fumes that come from the woods and the products you work with. Regardless of whether you operate an industrial woodshop or are a casual hobbyist, the danger of long-term exposure to toxic fumes from the wood you work with should not be taken lightly. 

In today’s blog, we further discuss the impact of toxic fumes in the woodworking industry and how Aeroex Technologies offers an engineered air filtration system that is capable of reducing toxic fumes from your woodshop facility.

Health Risks Associated with Toxic Fumes from Woodworking 

Wood Processing Fumes 

Exposure to toxic fumes can come directly from the constituents of coniferous trees such as cedar and pine woods. Wood dust particles is considered a Group 1 carcinogen according to the International Agency for Research on Cancer (IARC). Specifically, exposure to fumes from wood dust particles can result in health issues due to the natural chemicals of the wood and substances in the wood i.e. bacteria, molds, pesticides, and fungi being released into the work environment as fumes. 

Wood dust particles emit fumes in woodworking processes such as sawing, routing, sanding, and other operations, freeing microscopic particles into the shop that can irritate the eyes, noses, and mouth of your shop personnel. Toxic effects will range depending on the species of wood. 

Long-term exposure to cedar and pine wood fumes can exacerbate the symptoms of respiratory conditions such as asthma, and in some cases, can result in the permanent damage of lung tissue. According to the Canadian Centre for Occupational Health and Safety, Western red cedar, in particular, has been proven to contribute to the development of asthma. Plicatic acid is a common allergen and exposure to red cedar wood dust that contains this acid is what can cause an asthmatic reaction.

Case Study: Dundalk Leisurecraft 

Aeroex Technologies offers the expertise needed to ensure that the toxic fumes emitted from woodworking businesses are reduced in the working environment. 

Canadian manufacturer, Dundalk Leisurecraft specializes in building rustic, solid wood indoor and outdoor furniture, saunas, tiki bars, gazebos, and more – all constructed from maple, pine, and cedar. Dundalk reached out to our team about finding a solution for dealing with the toxic fumes that were being emitted into their work environment – specifically, from working with red cedar. 

Dundalk had a working dust collector in place, but their shop personnel were experiencing some of the symptoms associated with toxic fumes from wood dust. Their existing dust collector system was effective at collecting wood dust particles, however, it was also circulating toxic fumes from the wood dust around their facility. They needed an air filtration system that was able to mitigate the exposure of their shop personnel to these fumes. 

The Aeroex team of professionals assessed their shop needs and installed 2 IRIS-200 Air Purification Units that use activated carbon filters for ambient air filtration to remove the fumes in their workshop and keep the air clean. After the installation of the IRIS-200 Air Purification Units, the Dundalk staff noticed that the smell of the toxic fumes, as well as their symptoms, were substantially reduced.

Wood Smoke 

Some woodworkers finish wood using fire in their facilities to create a sought-after charred wood or shou sugi ban inspired effect – however, finishing wood with fire can leave woodworkers exposed to the negative health implications of wood smoke. 

Wood smoke is notorious for containing thousands of irritants and carcinogens such as polycyclic aromatic hydrocarbons (PAHs) and Benzopyrenes – both of which are toxic to humans. Like the effects of exposure to wood dust, exposure to wood smoke can cause eye, nose, and throat irritation in addition to headaches and nausea. Long-term exposure to wood smoke can also worsen the symptoms of existing respiratory conditions such as asthma.

Case Study: Montreal Bagels 

Montreal-style bagel businesses authentically produce their bagels by hand and in-shop. Using wood-fired ovens to cook these bagels is what gives them their notable flavour. However, the untreated wood smoke released from these ovens can lead to large environmental and health issues without an air filtration system. 

Luckily, Aeroex Technologies offers experience working with Montreal-style bagel businesses that use wood-fired ovens to produce their bagels. Our line of IRIS and ARO air filtration systems can keep wood smoke emissions at bay – mitigating the environmental and health risks associated with their untreated release.

Wood Treatment and Finishing Products 

Wood treatment and finishing products commonly used in a woodworking shop can also lead to health issues. 

In wood treatment, there are certain pesticides used as preservatives to maximize the service life of the wood. Small amounts of treated wood chemicals can escape or leach from the treated wood. The number of pesticide chemicals released from the wood will depend on a few factors. However, working with treated wood in a shop will exacerbate the release of these chemicals into the work environment as wood dust fumes – exposing you and your personnel to its effects. 

Wood finishing products such as oil-based stains, varnishes, and shellacs emit fumes that contain harmful volatile organic compounds (VOCs) that can degrade the quality of air in the shop and negatively impact human health. Breathing issues, nausea, dizziness, eye and throat irritation, and headaches are all potential symptoms of exposure to the VOCs in the fumes when using these products. Long-term exposure to these products’ toxic fumes can also result in wood stain poisoning with symptoms that include a burning sensation, blurred vision, and collapse, and cancer in more serious cases. 

If you’re concerned about exposure to toxic fumes from wood treatment and finishing products in your woodshop, consider Aeroex’s line of IRIS air purification systems. As in the case of toxic fumes from wood processing, IRIS purification systems utilize activated carbon filters for ambient air cleaning to remove toxic fumes and improve indoor air quality in your workshop. Get a quote for an IRIS air purification system today!

Air filtration system for Toxic Oil Fumes in Woodshop

As you can see above, there are a myriad of ways in which exposure to toxic fumes can occur in the woodworking industry. Long-term exposure and improper precautions to fumes from wood processing, wood smoke, and wood treatment and finishing products can negatively impact the health of you and your shop personnel.

It is for this reason that a proper air filtration system is in place to remove the presence of these particles and protect you and your workers from the long-term effects of exposure to toxic fumes in the woodshop. 

Aeroex air purification solutions target toxic fumes that are common in many woodworking facilities. We use multi-stage filtration techniques that target the sources of air quality issues. Our systems are designed to capture the smallest particles with the highest efficiency, and our made-in-Canada devices are designed to maximize the lifecycle of your filters (important given the volume of toxic fumes produced in large-scale woodworking operations). 

Models in our IRIS and ARO series are capable of mitigating the impact of toxic fumes using ambient or source-capture filtration. Aeroex offers the ability to augment any existing ventilation systems you have with an air filtration solution. This can be an option when you already have some mitigation measures in place at the source, but wish to improve the working conditions across your shop. 

Given the various options and models, we recommend that Aeroex get to know your operation to make a recommendation about the most affordable and efficient options. With over 20 years of experience and a variety of filtration media to choose from, we can assess your woodshop’s unique needs and offer you a tailor-made solution to remove toxic fumes from wood processing, wood smoke, and wood treatment and finishing products from your facility. 

To get started, contact Aeroex today.

 

 

Blog Mist Collectors
Introducing the BlowBox
November 12, 2021

Introducing the BlowBox – The Next Generation of Blow-Off Station

We recently introduced our brand new product line of blow-off stations – the Aeroex Technologies BlowBox was engineered with the manufacturing industry in mind. 

End users can simply place a machined part into the blow-off station, and using their own compressed air gun, are able to safely and efficiently clean the part without having to worry about also spraying airborne oil or coolant mist around your facility. 

Reduce Oil Mist Exposure, Improve Efficiency and Save on Maintenance Costs with the Aeroex BlowBox

Aeroex’s BlowBox utilizes motorized propeller suction – meaning on-demand airflow and no spool time needed, allowing end-users to clean more parts more efficiently between uses. 

At 24”x24”, the BlowBox is available in both table-top and stand options. Inside the unit is a HEPA filter, rated at 95% efficiency at 0.3 microns to capture any fine mist particles – mitigating exposure to the rest of your facility. 

When it comes to maintenance, the BlowBox only utilizes one consumable air filter, with current estimated life of 2 years. The remaining two Demister elements are easy to remove and rinse off once in a while (this will depend on use).

Where Other Blow Off Cleaning Stations Come Short 

Current blow off cleaning stations available on the market are pneumatic. Pneumatic blow-off stations also take longer to function as they require spool time, increasing the overall start-up time. Typically, users will have to shoot the air gun up in the air to get the fan spooled to blow their machine parts off. This means that users will have to wait longer in between uses to clean machine parts.  

The Impact of Long-Term Oil and Coolant Mist Exposure 

Ineffective air filtration of oil and coolant mist can lead to long-term exposure to your workers and facility equipment. Workers exposed to oil mist through skin contact, breathing it in, or ingesting it may experience irritation of the eyes and skin, mouth, and throat. Fever, increased heart rate, headache, and vomiting can also occur. Years and decades of unhindered exposure can also lead to the development of skin and respiratory disease and even cancer. 

Long-term exposure to oil and coolant mist will also negatively impact your shop equipment as it sticks and coats your machines. Besides increasing the likelihood of a slip and fall injury from occurring, this can result in the deterioration of your shop equipment over time, increased maintenance costs, and machine failure if not dealt with properly. 

If you’re interested in minimizing exposure to oil and coolant mist in your facility and reducing maintenance costs, consider Aeroex’s BlowBox blow-off cleaning station. Get in touch with an Aeroex representative today to learn more about this product line. 

Air Purification Blog
October 6, 2021

Reopening Businesses Safely With Air Purification

Reopening Businesses Safely With Air Purification

Businesses are still navigating the unknown of operating in the face of the COVID-19 pandemic, with changing public health policies and an evolving body of knowledge about the transmission of airborne viruses. Many workplaces have likely had to deal with some positive cases among their workforce, disrupted supply chains, or an abrupt change in reopening plans. With the economy entering new stages of reopening thanks to reduced case counts and increasing vaccination rates, there is now a need to pivot towards increased utilization of public spaces. The most successful businesses in this time will be those able to seize the opportunities of the new economy. Because COVID-19 and its variants cannot be eliminated altogether it is understood that reopening will carry residual risks related to the virus, and various methods of screening those COVID-19 risk factors are needed. As gathering restrictions are reduced and more workers and customers return to public places, new risks will emerge related to COVID-19 transmission and heightened expectations for workplace safety. Improving the ventilation of your business or public space with air purification will be a critical part of successfully adapting to this reality. 

Air Purification – Part of a Reopening Strategy

For a business owner or facility operator, there is no “silver bullet” to reopen. Instead, a suite of measures is needed to eliminate or mitigate the different threats of COVID-19. This is true for restaurants, shopping malls, offices, schools, medical centers, and other gathering locations. Air purification will be an important strategy when paired with other measures such as mask-wearing, social distancing measures, or hybrid work arrangements. Air purification will significantly reduce the risk of airborne COVID-19 transmission but is not a replacement for other public health measures or workplace best practices. The combination of strategies that you use in your workplace will depend on your operations but are likely to include a portable or industrial air purification solution given its effectiveness in reducing the transmission of airborne viruses. For example, check out our case study below on why the Ontario government is using HEPA filters like Aeroex’s as a way to scale back mask-wearing policy for low-risk cohorts.

What To Know About Air Purification for COVID-19 

Improving indoor air quality is a key way to reopen business safely because of how COVID-19 is transmitted. Per the CDC, viruses like COVID are transmitted when a contagious person breathes out droplets and very small particles that are carried through the air to recipients. Infections occur when this air is breathed in or received by other vectors. However, as reported by sources like the New York Times, medical-grade air purifiers (like those produced by Aeroex) with a HEPA filter can capture these small particles highly effectively. Particles that cause the virus are around 125 nanometers in size while a HEPA filter captures particles as small as 10 nanometers (the HEPA standard is 30 nanometers but a recent NASA study showed its highly effective past this). Therefore, deploying HEPA filter air purification systems like those produced by Aeroex in your workplace is an excellent strategy. Understanding the science of air purification and the root causes of COVID-19 transmission, buyers should be aware of claims from other technologies like UV lights that don’t prevent transmission – evidenced by recent controversies like the UV light recalls ordered by Health Canada.

How to Know What HEPA Filter To Use for Air Purification

While science shows the power of HEPA filters, the way they are deployed is important for success. There are many different public spaces in need of protection ranging from condo lobbies to the storefront of an independent business – in each case, the existing ventilation, air volume, and gathering size will be different. To prevent transmission, air needs to be purified at a rate that prevents particles containing the virus from staying too long in the air – this is measured by something called air exchanges per hour. To prevent transmission, an air purification system catered to your space must provide sufficient air exchanges. Aeroex is aligned with the ongoing research recommending ~6 exchanges per hour and uses tools like our volume calculator to propose the appropriate model with sufficient capacity. It is important to ensure that the HEPA filters used to provide this air exchange capacity, either using a larger unit or several small units where a large unit is not possible. Many companies claim to provide the HEPA efficiency, but not with the air exchanges you need. When deploying for locations with large open rooms, Aeroex typically uses models like our IRIS 4500, a unit that mounts into your existing ventilation systems and provides a primary MERV 8 carbon filter and a secondary HEPA filter with an efficiency rating of 99.97% at 0.3 microns. Other strategies include leveraging existing mechanical ventilation and choosing the right locations inside the room. If you do not have mechanical ventilation, we will help you to see a portable (non-mounted) model.

Case Study – Provincial Government Deploys 70,000 HEPA Filters in Ontario Schools

Medical grade air purification systems with HEPA filters like those designed by Aeroex are widely accepted as an industry best practice, which is why the Province of Ontario continues its deployment of HEPA filters in schools. To date, 50,000 have been deployed and another 20,000 are being deployed in time for the 2021 school year (as reported by Global News). The Province wishes to enhance the safety of schools and prevent the spread of COVID-19, using HEPA filters as part of a range of policies and measures. The Province is using air purification systems to enhance mechanically ventilated classrooms, as well as to provide standalone coverage in areas like cafeterias and gymnasiums that do not have mechanical ventilation. In the announcement by Minister of Education Stephen Lecce, highlights relevant to the case study included the following:

  • It’s another added layer of protection that recognizes that our youngest learners in this province will not be required to wear masks” – Stephen Lecce, Minister of Education
  • “Standalone HEPA filter units should be used in places where mechanical ventilation and improvements to ageing HVAC systems was difficult to achieve” – Ontario’s COVID-19 Science Advisory Table

Aeroex is a proud contributor to the fight against COVID-19 and high-quality classrooms for Ontario children. Our IRIS system is popular among public workspaces and institutions, including education, medical, government, and commercial buildings. Even before COVID-19, hundreds of our units were deployed in school boards, colleges, and universities across Ontario (we are an Ontario Education Collaborative Marketplace approved vendor). This has only increased due to the increased business case for deploying HEPA filters. To become part of Aeroex’s fight against poor air quality, contact us today to learn more about deploying our IRIS medical-grade air purification system. 

Air Purification
August 13, 2021

Industrial Odor Removal

Industrial odor control is a key determinant of a safe and healthy workplace and an indicator of the quality of your facility operations. In some industries, odors are a natural and important part of the business – examples here could include composting, cannabis cultivation, industrial food production, or wastewater treatment. In others, odors may arise as a result of equipment malfunction, incorrect batch ingredients, or other operational issues.

In each case, the odor has a direct impact on the products you distribute, the services your facility provides, and the way your staff and customers interact with your workplace. Odor is not always the first thing that comes to mind when industrial air purification is considered – often, issues like visibility, inhalation, and related safety concerns are top of mind. However, after consideration, it is clear that industrial odor control is necessary to maintain a safe and successful business. Therefore, attention should be paid to understanding your odor challenges and translating them to industrial odor control solutions.

Causes of Odor Issues

Odors are caused by volatilized chemical compounds traveling through the air. Typically, more volatile compounds have stronger bad smells. We smell odors when particles enter our nose, which usually occurs when odor molecules freely move through the air via diffusion (random movement in all directions, with a net flow from high concentration source areas to low concentration receiving areas). Sources of odor molecules may include cleaners, building materials, and aerosols. These particles tend to be incredibly small.

Odor control has been a source of some debate with 2020’s need to manage the COVID pandemic – some of the basic COVID control measures like masks do not mitigate odor – this is because odor particles are much smaller than those that cause COVID! Therefore, filtering the odor molecules that cause odor must be scaled to the causes of the odors themselves. Aeroex has a strong foundation in the science of odor causes and controls and has created an industrial odor control system (odor eliminator) matched to eliminate odors

Eliminate odors with our industrial Odor Control Solutions

The IRIS Series Medical Grade Air Filtration System optimizes indoor air quality, providing clean air by capturing the particles that cause odors, allergies, and other undesirable airborne contaminants like aerosols, particulate matter, microorganisms, and the previous discussed volatile organic compounds (VOCs). It accomplishes this through a highly engineered solution, recognizing that the particles that cause odor tend to be incredibly small (discussed above). Therefore, the filtration technique used needs to be small enough to eliminate those particles.

Our industrial odor control solution uses two progressive, powerful filters for removing odors. The first filter in the IRIS series is made of activated carbon, and as our primary filter, it has a MERV 8 rating (it will be followed by an even stronger filter in the second stage). Carbon fiber is an excellent odor eliminator because of its distinct ability to adsorb the particles it interacts with, chemically reacting and sticking to the filter. This is an important technique for odor control because it targets the root causes of odors rather than the odor itself. MERV 8 filters are excellent at targeting particles in the range of 3 to 10 micrometers – particles in this range typically include mold spores, dust, and cleaners – also known as the particles that commonly cause industrial odors!

The second stage filtration in the IRIS commercial odor eliminator machine is a high-efficiency particulate air (HEPA) filter with a 99.97% removal efficiency for particles with a size of 0.3 microns. This is the highest standard for air filtration systems and is referenced by guidance documents from leading organizations like the CDC. By removing larger particles first with the MERV 8 filter, the HEPA filter is then able to target the smallest particles that cause industrial odor.

To eliminate industrial odors you need an odor eliminator that efficiently filters the smallest particles, and the Aeroex commercial odor eliminator machine can do this at scale. Aeroex provides a range of models that are portable or can be centrally mounted, allowing you to employ source control solutions that are targeted odors nearby or ambient solutions that integrate into an existing HVAC system. The size of the unit will depend on the volume of your facility. Additional consideration could be given to how frequently you wish to cycle the air. Larger odor eliminators are often used where industrial odors are commonly associated with the workplace and occur throughout the building, such as a waste collection facility. Aeroex staff will advise on what unit is most efficient for you based on your operational context, but as a starting point check out our air purification requirements calculator for the IRIS system.

Trap odor molecules and Secure Your Workplace

Industrial odor control is an important issue, but the 2020-2021 pandemic has taught us that there are many other reasons to be concerned about indoor air quality in workplaces and public spaces. While industrial odor eliminators do not supplement government or public health guidelines, the medical grade status of the IRIS system means that it will minimize the presence of airborne infectious diseases, including COVID-19. The IRIS system is popular among public workspaces and institutions, including education, medical, government, and commercial buildings. Aeroex is proud to be able to support the efforts to fight COVID-19, with hundreds of our units being deployed in school boards, colleges, and universities across Ontario.

Evident from the discussion of the health benefits of medical-grade air purification is that there are many reasons to adopt an industrial odor control solution. As our awareness of workplace safety increases, so too does the need for air purification systems that attack the root causes of odors by filtering out the smartest particles. Aeroex achieves this while delivering a level of efficiency that helps to make an IRIS system a sound investment – our primary filters last 6 months and our HEPA filters last 3 years. The progressive filtration stages not only provide contaminant removal performance but also minimize the frequency by which you have to replace your HEPA filter. To learn more about industrial Odor control solutions, contact our team today.

Case Study
August 13, 2021

Case Study: Laker Energy LTD

Precision Machining Company in the Nuclear Parts Industry Uses Aeroex Oil Mist Collector for 15 YEARS WITH NO MAINTENANCE.

Laker Energy LTD was one of Aeroex’s first clients dating back to 2007 and after 15 years their original oil and coolant mist collector is still performing as strongly as the day they bought it. 

Laker Energy is a Canadian success story – founded more than 20 years ago, its 140 employees produce components for CANDU® nuclear power utilities around the globe using precision machining techniques. Laker Energy started their business supplying nuclear grade pipe, tubing, fittings, fasteners that hold up under pressurized operating conditions. To supply the nuclear industry, they are a CSA N285.0 certified Material organization and are a supplier of CANDU parts like fuel channel components, feeder components, and reactivity control components. Its mission is to provide best-in-class service that is safe, emphasizing quality and customer satisfaction. Their mission was a success, as they have since been acquired by BWX Technologies Inc., a large, 150-year-old US-based nuclear power and operations company serving the US government. You can find them at one of their southern Ontario machine shops or their Oakville headquarters. The Challenge

Today Laker Energy has a very large machine shop, but that wasn’t always the case. When they were starting in the 2000s their machine shop was much smaller and tightly packed. Because everything was so close together, even a small oil mist problem is going to feel big! Laker was running many cycles in their shop and had begun to observe ambient mist conditions over the day. Oil mist can become an issue for anyone, including Laker – if you are using higher tool speeds, applying fluid to cutting edges, and/or have higher workplace temperatures. Laker prioritized safety and quality and understood that issues with oil mist could include acute/chronic health issues, visibility, slippery floors and equipment, maintenance, work stoppages, and environmental pollutants.

The Solution

After identifying the oil mist issue, Laker Energy came to Aeroex for a reliable mist collector solution that would fit into their existing shop configuration. Laker Energy received one of Aeroex’s earlier models based on the design of the day in 2007. Key issues for Laker Energy in selecting an oil mist collector manufacturer were: 

  • A modular design that could fit into their “smaller” shop;
  • High quality to align with their customer needs in the nuclear industry, and; 
  • Reliable performance with minimal disruptions to their busy and growing business. 

Aeroex oil mist collectors use industrial air purification systems based on the science of how mist, vapors, smoke, and fumes behave when released, so Laker Energy was confident that the oil mist issue would be dealt with. However, they also needed a solution that addressed their key issues (above). The Aeroex oil mist collectors achieved this by:

  • Size Having flexible unit sizes and mounting options that can fit into any shop or machine. The modular design allows it to be a source control measure via mounting that occupies a very low shop footprint if you are short on space. Tubing can be used if desired, but it is generally not required – giving it that clean shop look.
  • Quality Aeroex is a made-in-Canada solution that uses the highest quality parts and manufacturing in the units they produce, a standard that Laker Energy expects from its equipment. Aeroex does not cut corners with cheap parts, and the thoughtful design enforces a quality mindset.
  • Reliability Aeroex uses multistage filtration that extends performance for years to come. Primary and secondary mechanical elements have an “infinite” life with some periodic handwashing, and the depth loading fibre bed is thick and durable enough to go for years without clogging thanks to the staging of primary elements that remove most oil mist.

The Results

Laker Energy knew they had the oil mist collection solution they needed, but the result went beyond their expectations. They now have many Aeroex oil mist collectors, but that first model they purchased back in 2007 is still going in 2021! It has run without disruptions for many machine cycles without major maintenance or filter changes, and it even made the move with them when they upgraded to a larger shop. Hear it first hand from a Senior Manager at Laker Energy, who said during an Aeroex shop visit that: 

  • “We purchased backup filters, and to this day we haven’t had to install them”!
  • “They run all day, every day (three shifts)”.
  • “No problems with clogging”.
  • “We use Aeroex for rough machining, which creates a lot of mist. We’ve tried a couple of other mist collectors in the past, but performance-wise they have longer cycle times than Aeroex.” 

Evident from the case study is that the result was a resounding success. The Laker Energy results demonstrate that Aeroex oil mist collectors truly are an investment that pays for itself, and even in rough machining operations, they outperform the competition with longevity for years to come. When Laker Energy chose their first oil mist collector, they never imagined it would still be running 15 years later to the same standard as when they got it! 

Apply the Case Study to Your Needs

If you are reviewing this case study, you are likely aware of your oil mist collector needs and maybe starting to refine your search to a final model. Aeroex understands that selecting an oil mist collector manufacturer and model can be a difficult process. The industry has its language and performance standards with various companies making claims about what is being provided or omitting key details. The Laker Energy case studies prove the standard Aeroex provides is transparent and lives up to its promise. Aeroex oil mist collectors are an excellent investment with high performance and a better life cycle than other brands, as Laker Energy experienced firsthand. If the Laker Energy experience sounds like something you want for your operation, reach out to our team today to get started. 

Case Study
August 13, 2021

Case Study: Benmur Precision Tooling

Oil Mist Collector Helps Waterloo Machine Shop Perform Fly Cutting Machining. When Benmur Precision Tooling stepped up their machining operation to fly cut larger products for a client in the tech sector, oil mist quickly became an issue. They came to this oil mist collector manufacturer for an industry-leading air purification system at an affordable price.

Established in 2008, Benmur Precision Tooling is a specialty machining shop located in Waterloo, Ontario – the “Silicon Valley North” of Canada. Benmur uses 5-axis CBC milling like the Kitamura 4xD to produce components, housings, hardware assemblies, and many other products. They work for clients across southern Ontario in industries like nuclear, automotive, food manufacturing, lasers or optical systems, and digital projection. Notable clients include Nikon, North + Google, and the University of Waterloo. Benmur serves this industry with machining techniques like lathe turning, injection mold making, grinding, polishing, waterjet cutting, anodizing and coating, mig and tig welding, and of course multi-axis machining.

The Challenge

When Benmur Precision Tooling was commissioned by a company in the local tech sector to produce a larger specialized part, they got straight to work with a machining program that required fly cutting. Fly cutting is a machining technique in which a single point cutter is used on a mill, often to produce a surface finish when a face mill can’t get the job done at the right cost or scale. Its larger diameter means that you can get a great finish for your product in a single pass. This was the main driver for Benmur selecting fly cutting as the technique for their client, as the products Benmur had to machine were fairly large. Unfortunately for Benmur due to the scale of the production and the technique involved, the buildup of oil mist as a byproduct of machining became too much. Oil mist built up in the machine and was released into the shop, leading to work disruptions 3 to 4 times a day as staff tried to deal with the oil mist. It became clear that if Benmur wanted to produce large parts requested by its clients, the problem had to be addressed –both for operational efficiency, quality, and health and safety. Benmur did not have an oil mist collector but knew that they could not continue to operate in a shop with machines overrun by oil and coolant mists.

The Solution

When Benmur Precision Tooling needed an oil mist collector, they came to Aeroex as the mist collector manufacturer who could meet their needs with an affordable, made-in-Canada solution that would fit right into their shop. Aeroex examined Benmur’s needs to understand what type of pollutants they were experiencing, what sources of pollutants had to be controlled, the size of the operation, the volume of the building, the types of machines they had, and what ventilation was in place. This was compared against the suite of oil mist collector products Aeroex offers to select the best model with the best value for Benmur. After consultation, Aeroex recommended the Mist-Fit 550 oil mist collector, an option that was compact yet high performing, affordable, and ideal for high-pressure coolant and oil applications.

The Mist-Fit is an Aeroex oil mist collector that eliminates mist, smoke, and fine particles caused by machining. It eliminates oil mist through four consecutive stages of filtration, each providing a layer of operational efficiency. The first two elements eliminate up to 95% of mist by disrupting the flow, quickly causing droplets to condense and drain out of the filter stages back to the sump of your system. With much of the oil mist already eliminated, the third-stage fiber bed can work in optimal conditions to capture small, sub-micron-sized particles (0.3 um) with 95% efficiency. The depth loading fiber bed has a significant thickness, meaning it has a very long useful life and high removal efficiency thanks to the amount of filter media – not to mention lower oil mist concentrations after the first two stages. This is in stark contrast to competitors who often use thin filters without primary filtration, resulting in frequent clogging, maintenance, and filter replacements. If your system is releasing the smallest smoke and fume particles, an optional HEPA filter is staged after the fiber bed to finish the job. To learn more about the design features of the model Benmur selected on Aeroex’s recommendation check out the product page. The information contained within demonstrates the design features of the solution and the efficiency it offers the end-user.  

The Results

After a quick and easy installation (approximately one hour to mount the new unit), Benmur immediately noticed the improved operations of the shop and the virtual elimination of the oil mist that had become a big issue during their previous fly cutting. As time went on, they also discovered the low maintenance and operating costs of the Mist-Fit, one of the key benefits they cited in their debrief with Aeroex about their experience with the Mist-Fit. As shown in the breakdown of the Mist-Fit design (above), the Mist-Fit oil mist collector was specifically designed to deliver on performance without the frequent maintenance commonly associated with other models. The result was Benmur Precision Tooling continuing to operate in their Waterloo shop for their many tech sector clients.

Apply the Case Study to Your Needs

Those interested in the Benmur Precision Tooling case study should know that challenges with oil mist during machining are not unique to them. You may be experiencing newfound challenges for the first time as you branch out into new techniques, products, and service volumes, for example, if you are starting to incorporate high-pressure coolants. Like Benmur Precision Tooling, you will find that there are solutions available to you and experts ready to help you navigate your need for an oil mist collector. If you think this is you and you’re ready to get started, contact Aeroex today.

Case Study
August 12, 2021

Case Study: Lauer Machine

Coolant Mist Collector Helps Machine Shop Expand Into High-Pressure Coolant Applications. When Lauer Machine added high-pressure coolants for their machining operations, they went to Aeroex to supply an oil mist collector that would keep their staff, equipment, and the environment safe.

Case Study Profile

Started in 1973 as a single-person operation, today Lauer Machine is a modern machine shop providing vertical and horizontal milling, lathing, measurement analysis, cylindrical grinding, and many other techniques using materials like stainless steel, aluminum, copper, and even bronze or titanium. Operating under the motto of “manufacturing beyond expectation”, the work done by Lauer is frequently recognized by their clients like Husking Injection Molding Systems Ltd. You’ll find them at their 10,000 square foot shop in Orangeville, Ontario.

The Challenge

There comes a time when every machining shop begins to implement high-pressure coolants, and a strong performing and growing company like Lauer Machine is no exception. It could be at times like when you landed that important client who orders materials outside your usual selection, such as titanium. Unfortunately, the standard machining approach without high-pressure coolant will typically lead to chip formation. Chip formation is caused by material failures that do not conform with the machine cuts being made, resulting in the accumulation of chips in the workspace. High-pressure coolant addresses the issues of chip formation and size by helping the materials and tools to transmit heat away from the machining zone, reducing chip formation and the wear and tear on your tools.

High-pressure coolant is an excellent technology to utilize and the logical choice for your process. However, it poses safety and operational challenges. Coolant can vaporize under high temperatures, entering your equipment and creating a thin film of oil. When released, oil mist poses both safety and environmental concerns. Like those that came before them and those that will come after, Lauer found that the application of high-pressure coolants warrants an oil mist collector that mitigates the risks.

The Solution

After learning about the challenges with oil mist at Lauer Machine, Aeroex took time to understand Lauer’s operation before recommending the optimal solution with the best value – ultimately landing on the Mist-Fit 550. To learn about the specifics of the model, check out our product pages. For now, understand that air purification is best done in stages and Aeroex has designed a multi-step process of removal with increasing efficiency using materials that limit your maintenance costs, such as the use of thick depth loading fiber beds rather than thin pleated face loading filters that keep you coming back for costly filter replacements. 

Aeroex supports many industrial air purification needs for various substances, but in the case of Lauer Machine, the oil mist from high-pressure coolant was the issue of concern. The Mist-Fit was the best solution for them because it promotes drainage of larger particles before attacking the smaller particles with MERV 15 and HEPA-rated filters. This is because while the majority of oil mist particles range from 1 to 100 microns in size, many are below 1 micron and therefore aren’t addressed by conventional air purification systems. If your application is producing oil smoke, particles as small as 0.3 microns need to be filtered (hence the HEPA filter). However, if you start with a very fine filter it will immediately clog, which is why the progressive design of Mist-Fit maximizes the efficiency of both the oil mist removal process and the need for maintenance with filters that do not clog. Understanding this, Aeroex and Lauer Machine deployed the Mist-Fit 550 (sized according to the cubic feet of air handling needed for Lauer’s machines and shop size) to great success. 

The Results

At the beginning of the case study, Lauer Machine had transitioned to high-pressure coolants and found themselves employing extra safety measures and equipment maintenance to keep up with the oil mist. After installing the Aeroex oil mist collector, Lauer immediately reported the oil mist issue was resolved. Another year of operations later and Lauer said in their own words that:

  • The Mist-Fit was incredibly easy to install.
  • The Mist-Fit had been running continuously for a year with no issues.
  • Aeroex mist collectors are powerful enough to draw air from the surrounding shop, as well as the machine it’s mounted to (when not running).
  • “For any machine with high-pressure coolant or a smoky environment, these are definitely the way to go”!
  • “If you want to keep your employees happy, you need these things”!

To see for yourself, check out the shop visit video hosted by Lauer Machine in Orangeville.

Apply the Case Study to Your Needs

As documented by Production Machining (2004), high-pressure coolants are still a relatively recent industry advent that only became common practice for small to medium-sized shops in the early to mid-2000s. With any new technology, there are always unintended consequences or side effects like oil mist during machining, and the best ways to manage these were subsequently addressed by companies like Aeroex during the increasing awareness of safety and environmental workplace issues. Setting the challenges of new technology aside, for any expanding company it is normal to experience growing pains and one day realize you need an oil mist collector due to high-pressure coolants (as was the case for Lauer Machine, an expert machine shop). Rest assured that Aeroex understands your challenges and is ready to help meet the moment with a made-in-Canada solution – contact us today to get yours!

Case Study
August 10, 2021

Case Study Profile: Grimsmo Knives

Grimsmo Knives was looking for an air filtration solution that would efficiently filter out the oil and coolant mist from their shop facility. Aeroex Technologies installed 2 Mist-Fit MF-550 mist collector units to vastly improve the air quality and mitigate the negative impacts associated with long-term exposure to oil and coolant mist on shop equipment and personnel. 

Learn More About: Grimsmo Knives

Grimsmo Knives is a Canadian-based knife-making business that specializes in machining premium knives and gear. John Grimsmo started the business in his garage over a decade ago, dedicated to learning how to make knives and sharing his journey to becoming a self-made CNC machinist on Youtube. John’s Youtube videos include everything from knife making, how-to, shop vlogs, manufacturing shows, and more. 

Now with 72.3 thousand Youtube subscribers, John’s knife-making business has grown in staff and product offerings. The Norseman, The Rask, and The Saga Pen are all machined in-house at the Grimsmo Knives facility in Stoney Creek, Ontario. 

The Challenge

Like many shops that house CNC and metalworking equipment, Grimsmo Knives wanted to reduce the risks associated with long-term exposure to oil and coolant mist on shop personnel and equipment. Oil films can form on equipment, increase the risk of slip and fall accidents, and can irritate the skin, eyes, mouth, throat, and lungs of shop personnel. Long-term exposure to oil and coolant mist has been shown to increase the risk of developing skin and respiratory diseases, including cancer.

Midway through the video, we learn that the air quality at Grimsmo Knives feels “swampy” due to the increase in the buildup of oil and coolant mist in the air when machines are in operation. The air quality was tested at the beginning of the workday at 0.8 mg/m3. While this result is below the recommended limit set by OSHA of 5.0 mg/m3, most companies and health and safety committees agree that exposure limits should range from 0.3-0.5 mg/m3 – which puts Grimsmo Knives above the recommended industry range.   

The Solution

A team of engineers and specialists assessed Grimsmo’s Knives facility to find them the best oil and coolant mist collector solution that would vastly reduce exposure to oil and coolant mist, and improve air quality. 

2 Mist-Fit MF-550’s (550 CFM) were installed strategically at Grimsmo Knives shop facility to promote airflow. The Mist-Fit MF-550 uses multi-stage filtration to remove oil and coolant particulates and is capable of moving 1 unit of air every 15 seconds. Stage 1 of the filtration process features a smooth mechanical element engineered to disrupt and remove wash and swarf. Stage 2 utilizes a special wire mesh to encourage the formation of droplets – making it easier to drain. At this point, 95% of the oil mist has been removed. Finally, Stage 3 features a thick fiber bed filter that collects 95% of particles that are between 1 to 3 microns. There is also an optional Stage 4 HEPA filter that can be added to target sub-micron particles – typically used for facilities and shop environments where there is smog prevalent. 

The Results

Once the 2 Mist-Fit units were installed at the Grimsmo Knives facility, the air quality was tested again at 0.010 mg/m3 indicating a large drop in oil and coolant mist in the air when compared to the air quality tested earlier that day. 0.010 mg/m3 is well below OSHA and the majority of health and safety committee standards for oil and coolant mist exposure ranges – therefore mitigating the risks associated with long-term exposure at the Grimsmo Knives shop.  

The Grimsmo Knives is now able to operate in a shop environment with cleaner, safer air for both personnel and equipment. 

Apply the Case Study To Your Needs 

The issue of long-term exposure to oil and coolant mist isn’t just unique to Grimsmo Knives. The increased use of high-pressure coolant systems within the metalworking industry has contributed to the negative effects of long-term exposure of oil and coolant mist on staff and equipment. To ensure the health and safety of your shop personnel, and the working life of your CNC and metalworking equipment, we recommend opting for an industrial mist collector that meets the demands of your everyday operations. 

Luckily, Canadian-based Aeroex Technologies is a dedicated oil mist collector manufacturer that is committed to ensuring that your facility’s air quality is safe for your staff and equipment. Our team of engineers and specialists will assess your shop needs and offer an oil mist collector solution uniquely suited to promote air quality and limit exposure to oil and coolant mist. Get in touch with an Aeroex Technologies representative today to learn more! 

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