Blog Mist Collectors

What are mist collectors?

What are mist collectors?

Mist collectors are industrial-grade machines designed to remove airborne particles from industrial working environments. While more commonly found in the metalworking industry, innovation in mist collector technology has also enabled their utility in other industrial applications including commercial food production, air purification, and other specialty uses. 

Businesses that rely on machining processes that emit harmful pollutants must ensure that the working conditions, including indoor air quality (IAQ), are compliant with contemporary exposure standards set by regulatory bodies like the Occupational Safety and Health Administration (OSHA), the National Institute for Occupational Safety and Health (NIOSH), American Conference of Governmental Industrial Hygienists (ACGIH) and Health Canada. For instance, OSHA limits exposure to 5 mg/m3 for all employees that work 8 hours/day and 40 hours/week, and any employer that does not comply with these restrictions could risk a lawsuit or fines. Health and safety committees work to achieve a recommended limit of 0.3-0.5 mg/m3 to provide a safe working environment. To be certain that your industry stays within the stated guidelines, an industrial hygienist should be consulted to determine the air quality in your environment. 

Luckily, Canadian-made Aeroex Technologies Inc. has engineered mist collectors for a large range of industrial applications in addition to metalworking, such as commercial food production, air purification, and other specialty uses that are compliant with the standards set by these regulatory bodies. 

 

Tsugami Mist-Fit

MIST COLLECTOR MF-350 ON TSUGAMI

Where are mist collectors used?

Mist Collectors in the Metalworking Industry

Mist collectors used in the metalworking industry serve to trap harmful oil and coolant mist that is formed during machining processes. Oil and coolant mist exposure poses a significant health hazard risk to personnel and shop equipment. Regular and proper maintenance of metalworking machines can cut down on production time and aids in preventing machine failure. One way machine operators ensure proper maintenance of metalworking machines is by keeping their metal cutting tools lubricated. This keeps metals cool while in action, reduces friction, and protects their integrity in the long term. 

Amid machining processes such as milling or grinding, oil or coolant mist may be generated and can easily disperse throughout the work environment. When exposed to high temperatures, oil mist can develop into oil smoke in which the oil begins to burn before it is released into the air. This can pose a great health risk to machine operators and can contaminate CNC machine assets. Oil mist exposure can also leave behind a slick residue on the machines as well as the working environment. Slick working conditions can damage machines, as well as increase the risk of slips and falls occurring if not properly controlled.

Exposure to oil mist can occur through skin contact, breathing oil mist in, or ingesting it. People that are exposed to oil mist can experience symptoms such as irritation of the eyes or skin, a burning sensation in the mouth and throat, fever, rapid heart rate, shortness of breath, vomiting, and headache. Long-term exposure to oil mist can also increase the likelihood of developing skin and respiratory diseases, as well as cancer. With a growing shift in the industry toward the use of high-pressure coolant systems, many mist collectors on today’s market fall short in their ability to filter through the byproducts these coolants produce. 

Fortunately, Aeroex Mist Collectors are made to effectively remove byproducts that are produced by high-pressure oil and coolants used in metalworking processes to mitigate the risks associated with oil mist exposure. Aeroex Mist Collectors are built to be durable and low-maintenance to meet the everyday demands of your facility’s regular operations. Regardless of machine size, Aeroex Mist Collectors can be fitted to meet the needs of your equipment and can be customized with accessories that further ensure quality air filtration.

Mist Collectors in Commercial Food Production

Mist collectors can also be used in commercial food manufacturing processes to remove cooking odours, grease, smoke, and oil mist from food production facilities and commercial kitchens. Hygiene is essential when it comes to food and beverage processes – ensuring a sanitary work environment is imperative to reduce the risk associated with contamination necessary for quality. Moreover, clean working conditions allow your equipment to work at peak performance while also maintaining a safe work environment for employees. 

Requirements for businesses to meet air purification and oil collection standards in commercial food production will depend on a myriad of factors. Many businesses will seek professional advice when it comes to health, safety, and environmental standards concerning air purification and oil collection. Aeroex engineers offer years of experience in outfitting commercial food production facilities with air purification and oil collection solutions that meet the specificity of food production industry standards. Air purification systems can be equipped with Oil Extractors and other accessories needed to ensure your machines are fully capable of meeting everyday air filtration demands.

Mist Collectors in Speciality Applications

The modular nature of Aeroex Industries air purification systems allows great flexibility when it comes to outfitting the needs of specialty filtration applications. Fume extraction in laser engraving, 3D printing, plastic welding, wet scrubber exhaust, mobile applications, odour and fume control, cold heading, stamping, heat treating, and parts washers applications can all be custom outfitted with Aeroex air purification solutions to control the release of undesired airborne particles such as mist, smoke, aerosols, fumes, odours, and exhaust. 

Mist collectors are vital for maintaining air quality standards in metalworking, commercial food production, as well as a myriad of specialty applications. It is no wonder why more and more businesses are seeking effective ventilation of unwanted airborne particles by opting for a mist collector machine that is compliant with industry air quality stands.

How Do Mist Collectors Work?

Many mist collectors work by using centrifugal technology where a rotating drum is used to intercept unwanted particles and merge into larger droplets that ultimately drain out of the unit. The disadvantage to centrifugal separation is its inability to separate fine mist particles. This is often supplemented with an afterfilter. The downside to relying on an afterfilter to eliminate fine mist particles is short filter life leading to diminished airflow. To maintain operational performance these mist collectors require frequent service with a high cost of consumables. 

The engineering experts at Aeroex Technologies Inc. have found a solution by using innovative filtration techniques and cutting-edge materials to ensure high-efficiency mist collectors that can maintain consistent airflow with industry-leading maintenance intervals. Aeroex mist collectors feature several innovative design elements that guarantee high efficiency, the extensive lifespan for its filters, and low operational costs. Design elements such as; first-stage mechanical element filters use inertial separation technology to drain up to 85% of contaminants from the airstream before entering consumable filters. Further filtration is achieved by using depth loading fiber bed filters to progressively capture the remaining mist particles, consolidate them to a central drain for return to the machine sump.  

Source Capture vs. Ambient Capture

In air filtration, source capture and ambient capture refer to where the air filtration takes place. As its name would suggest, source capture filtration occurs at the source where unwanted airborne particles are produced. In contrast, ambient capture works by continuously circulating plant air through overhead filtration units.

The main benefit of choosing a source capture mist collector is that it eliminates the mist directly at the source. This is a much more efficient and cost-effective solution. 

With ambient capture, the contaminants are allowed to exit the machine and circulate through the facility before it is captured by the ambient air cleaner. .. That’s why Aeroex designs machine-mounted mist collector solutions to effectively and efficiently capture air contamination at the source.

What Factors Should I Consider When Purchasing a Mist Collector?

Are you in the market for a mist collector for your unique application? Choosing a mist collector that meets your demanding day-to-day operations can feel overwhelming. However, meeting industry air quality standards and ensuring the safety of employees, equipment, and their working conditions should never be overlooked regardless of the industry you work in. The following, are guidelines that industries should look out for when purchasing a mist collector:

Air Quality Standards and Filtration Capability

  • The efficiency or MERV rating of filters indicates the specific size of particles in microns that can be collected by the mist collector. 
  • Delivered Airflow indicates the amount of airflow that a mist collector can intake factoring airflow loss with filters installed. Usually measured in cubic feet per minute (CFM).
  • Minimum particle size is measured in micrometers. Signified with the unit µm, they show the minimum diameter of aerosol that a mist collector is capable of filtering.

Air Purification requirements can be determined using our calculator.

Application, Size, and Weight Specifications

  • Consider what size mist collector you require to meet the needs of your industrial application. Use our calculator to help you determine which is the best unit for your specific needs. 
  • Size specifications indicate the dimensions of the mist collector unit. They are usually measured in feet (ft) and inches (in), and they go a long way in helping to determine the positioning and mounting opportunities available. 
  • The weight of the mist collector in pounds (lbs).

Sound Level Considerations

  • The sound levels of mist collectors are also indicated to show the amount of noise that it would generate while operational. This is measured in decibels (dBA). Top-of-the-line mist collectors aim to reduce noise levels as much as possible.

Power and Usage

  • Power specifications refer to the voltage requirements to power the mist collector and should be matched based on the power supply available at the facility.
  • Maintenance intervals will determine how frequently the filter must be cleaned or replaced.

Installation Options

  • Installation indicates how the mist collectors are to be mounted and connected for optimum performance. Generally, numerous mounting options will be available to accommodate the wide range of applications.