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Tag Archives: Fume extractor

Soldering Fumes
Categories Fumekiller Author poweradmin 0 Comments

Health hazards of soldering fumes

Operators doing soldering can be exposed to lead during the process. If handled improperly, lead can have long-term negative consequences on one’s health, including issues with the reproductive system, the digestive system, memory and concentration, and discomfort in the muscles and joints. Operators can be exposed to the fumes by means of ingestion or inhalation.

Hazardous dust and fumes can be produced when soldering with lead (or other metals used for soldering). In addition, using flux containing rosin produces solder fumes that, if inhaled, can result in occupational asthma or worsen existing asthmatic conditions; as well as cause eye and upper respiratory tract irritation.

Today’s world places a great deal of importance on the skill of soldering. From jewellery to construction to electronics, soldering is used in a wide range of sectors during the manufacturing process. As a result, in order to better safeguard workers from potential danger, the health impacts of soldering have been thoroughly researched.

It has also been discovered that extended exposure to soldering fumes can be harmful for people, lead to major chronic health issues, and exacerbate existing chronic diseases.

What are solder fumes?

Solder fumes are metal vapours expelled into the air as a result of the heat + pressure of soldering. The actual process of soldering involves the melting of metals to create a strong joint. As a result, soldering fumes are released into the air as the solder flux transforms into a gas.

Why are Solder Fumes Considered a Health Hazard?

Anything you breathe other than clean air that will likely be detrimental for your health. However, heavy metals found in soldering fumes can be quite harmful to people. Therefore, it is generally agreed that soldering fumes pose a significant risk to occupational health, and employees should be shielded from these side effects using sufficient ventilation, fume extraction, and personal protective equipment (PPE).

Soldering Fumes Health Effects:

The type of metals used in the soldering process has a significant impact on the health effects of soldering fumes. All heavy metals have the potential to be hazardous if consumed, however not all heavy metals are equally toxic, and the toxic dose might vary. For instance, even though iron is an essential part of our diet, those who consume excessive amounts of it might develop iron toxicity. However, lead exposure can result in a wide range of health issues as lead is a highly poisonous substance. People exposed to lead run the risk of developing renal disease, hypertension, and digestive issues even if acute lead poisoning does not manifest. Beryllium, another heavy metal that is utilized in various applications, is known to cause cancer.

The symptoms are generally flu-like, with fever, aches, chills, nausea, and dizziness.

Many other elements and compounds used in the soldering process can be potentially harmful and therefore, it is wise to treat all fumes as toxic and prevent the inhalation of soldering fumes in general.

The Occupational Safety and Health Administration (OSHA) standard requires employers to monitor air quality and restrict soldering fume exposure. The permissible exposure limit (PEL) is strictly enforced by OSHA in order to promote safe working conditions.

Soldering fumes are an occupational health hazard caused by heavy metal dust and smoke that can be breathed in. A worker who does soldering as a part of their job will require a working environment where all protective measures are in place. Some of these measures include:

  • Ensuring proper ventilation throughout the shopfloor.
  • Have enough PPE for personal protection of every operator.
  • Use of soldering fume extractors is a must at every soldering station.

At Powertech Pollution Controls Pvt. Ltd., we provide a variety of mobile and fixed fume extraction devices, under the brand name of FumeKiller® that are highly effective and efficient in the capture and control of fumes, smoke, mist and dust. Our FumeKiller® devices can be used for extraction of fumes in processes like hand-soldering, wave-soldering, dip-tinning, automated soldering stations etc.

Some of our reputed customers include India Nippon, Delta Electronics, Secure Meters, Lucas TVS, Centum Electronics and Rakon India, among others.

For any requirement for soldering fume extractors, Get in Touch with us today and we will work with you to design the most suitable solution for your requirement.

Categories Fumekiller, Welding fume extractor Author poweradmin 0 Comments

Dangers of welding fumes and protecting health of welding operators

Introduction:

Welding plays a crucial role in creating strong and durable metal joints and is a critical process in multiple industries ranging from construction and manufacturing to automotive and aerospace. However, there is a significant health risk that is posed to the operators because of the toxic fumes generated during the welding process. In this post, we explore the dangers of welding and potential solutions to avert these dangers and create a cleaner and safer working environment for welding operators.

The Hidden Dangers of Welding Fumes:

Welding involves joining of metal joints using high levels of heat and the process itself can generate a significant volume of harmful and potentially toxic fumes and gases. Some of the most common types of welding fumes include:

  1. Metal Fumes: Tiny particles of metal become airborne during the welding process. These particles may include hazardous elements like Chromium, Lead, Cadmium and Manganese.
  2. Gases: Various gases, such as Nitrogen Oxides, Carbon Monoxide and Ozone can form during the welding process. Prolonged exposure to these gases can have serious side effects in the long term.
  3. Volatile Organic Compounds (VOCs): Organic compounds like benzene and formaldehyde that are released during welding are known carcinogens.
  4. Particulate Matter: Other than metals, there may also be other microscopic particulate matter in the fumes generated from welding. These particles can be inhaled and can cause long term respiratory issues and lung disorders.

The Effects on the Health of Welding Operators:

The potential health risks to welding operators who are exposes to fumes over extended periods are multiple and can be quite severe. Some of the more commonly observed issues include:

  1. Respiratory Problems: In the short term, problems like cough and irritation of the throat is quite common when exposed to welding fumes. However, prolonged exposure can lead to severe chronic conditions including bronchitis, asthma and even lung cancer.
  2. Neurological Effects: Long term exposure to Manganese in the welding fumes can lead to a condition known as “Welder’s Disease” or Manganism, a condition resembling Parkinson’s Disease, with symptoms like tremors and difficulty with movements for those affected.
  3. Metal Poisoning: As explained earlier, welding fumes can contain a multitude of heavy metals like Chromium and Lead. These can accumulate in the body over time and lead metal poisoning and severe health complications.
  4. Eye and Skin Irritation: A commonly observed effect of welding fumes is irritation of the skin and eyes which are usually short term issues but can potentially cause problems in the long terms as well.
  5. Reproductive and Developmental Disorders: Some studies suggest that fertility issues and developmental disorders in unborn children may be linked to prolonged exposure to welding fumes.

How to Protect the Workers in the Shopfloor?

Given the serious health hazards that are posed by welding fumes along with the obvious environmental effects, creating a clean and safe working environment for welding operators becomes a crucial task. One of the most effective methods of achieving this goal is to implement a fume extraction system for welding fumes. Here are some of the benefits of using a fume extractor.

  1. Worker Safety: The most immediate and obvious result would be providing a clean and safe workspace for the welding operators.
  2. Regulatory Compliance: Many countries have introduced strict regulations regarding workplace safety and air quality. Installing a welding fume extractor would be the quickest way to comply with these regulations.
  3. Improved Productivity: Clean air leads to a healthier workforce, which would thereby create a potential for improved productivity and operational efficiency.
  4. Cost Savings: This is more of an indirect effect where the cost of healthcare expenses and potential legal liabilities can be minimized.
  5. Environmental Responsibility: While preventing welders from being exposed to welding fumes, a fume extractor would also ensure cleaner air within the shopfloor, to a certain degree.

How can We Help?

Here at Powertech Pollution Controls, we have over 25 years of expertise in providing solutions for issues related to air pollution control. The FumeKiller® is an electrostatic filtration system and as the name suggests, its primary function is as a fume extractor. It finds use in processes like welding, soldering, brazing and even as an oil mist collector for CNC machining operations.

As a welding fume extractor, the FumeKiller® unit can be placed in a fixed location with a suction hood placed between 6 – 8 inches from the fume generation point for effective and efficient extraction of fumes. Alternatively, in situations where the welding location may change, the unit may also be manufactured in a vertical orientation with wheel mounting and equipped with our Flexible Extractor Arm, to be used as a portable fume extractor. It is a matter of great pride for Powertech that over the years, we have been able successfully implement the FumeKiller® unit as a welding fume extractor over a wide range of applications for a multitude of clients. In spite of our vast experience, we continue to approach each new project as a unique requirement and design each solution accordingly.

Conclusion:

It is important to recognize that the risks posed by the toxic fumes produced during welding processes are numerous and potentially severe. If welding operators are not sufficiently protected from these threats, they run the risk of serious health problems. Fume extraction systems are essential for protecting worker health and ensuring regulatory compliance, and not merely as a suggested safety measure. By investing in fume extraction systems like our FumeKiller® unit, businesses can prioritize employee health and safety while simultaneously fostering environmental. In the end, safeguarding employees from the unseen dangers of welding fumes is not only a moral obligation, but a wise business move as well. If you have a requirement for a fume extraction system, Enquire Now and our team will get in touch with you to work out the best possible solution.

Categories Mistkiller Author poweradmin 0 Comments

Application of FumeKiller® as an Oil Mist Collector

At site, 8no.s of CNC machines in a row had to be provided with suitable mist collectors. All CNC machines generated mist / fumes from neat cutting oil which had to be captured and the pollutants in the fumes are to be filtered effectively. 

Our FumeKiller®, electrostatic filters are well-suited to capture and control fumes generated during machining processes in CNC machines. These fume extractors can be used for the control of oil mist (neat cutting oil) as well as coolant mist (water-based coolant). Lower suction capacity fume extractors (FumeKiller®) can be installed for individual CNC machines. In case of multiple CNC machines larger capacity fume extractors can be installed along with suitable ducting to capture and route the generated fumes from the CNC machines to the oil mist collector (FumeKiller®). For neat cutting oil fumes, we always recommend Dual-pass electrostatic filters to provide high-efficiency filtration of fumes / mist. For water-based coolant fumes / mist single -pass filtration extractors work satisfactorily.

The installation was carried out using our FumeKiller® model FK6000/5hp mounted on a low MS angle stand with a large oil collector tank below the stand. MS ducting was mounted above the row of CNC machines with droppers to connect individual CNC machines. Last- mile connections were provided using PVC flexible hose. Even though our standard FumeKiller® model FK6000/5hp uses a 3HP motor to drive the suction fan, in this case we used a 5HP driven suction fan to provide higher static pressure because of the length of ducting involved.  

It was found that for a 2-shift operation, the filters within the oil mist collector filtered the pollutants for 4 weeks before getting choked. The cleaning cycle for the filters was established at 4 weeks. Just before getting fully choked, the filter module as well as the prefilters and postfilters are removed and cleaned using pressure water pump at about 110bar pressure. The filters are dried using a compressed air jet and repositioned inside the fume extractor. Adequate training was given to the maintenance technicians to handle the equipment. All safety features were explained and demonstrated. The equipment was found to be working satisfactorily.

Visit us: https://www.powertechindia.com

Fumekiller
Categories Fumekiller, Welding fume extractor Author poweradmin 0 Comments

Control of Component Welding Fumes – Fumekiller® model FK3600EM as a Welding Fume Extractor

The special purpose machine has two adjacent component welding stations. The welding fume generation area is open, without any enclosure. The welding process takes place only at one station at a time. The jobs are loaded manually by a skilled operator. During welding fumes are generated which are to be captured and the pollutants in the fumes are to be filtered effectively.  

Our Fumekiller®, electrostatic filter model FK3600/3hp was suggested to be mounted on an MS Grouted pipe stand of about 5ft height positioned just behind the welding machine. Two MS painted suction hoods were placed just above the two welding stations at a convenient height after studying operational comfort as well as optimum fume suction distance. The suction hoods were connected to a common MS ducting fitted to the Fumekiller® equipment and supported from the fume extractor.

The fume extractor was switched on during the welding process. The welding fumes generated at the two component welding stations were captured by the fume extractor through the 2nos of suction hoods placed above the welding spots effectively. The fume extractor should be operational as long as the welding process is being carried out.

The welding fumes consisting of various pollutants such as manganese, chromium, nickel, and other potentially harmful elements, enter the electrostatic filter (Fumekiller®) through the air stream. The ionisation section of the filter charges all particles 0.01 micron and larger in the air stream. The air enters the collection section where the pollutants adhere to the collection plates. Pollutants as small as 0.01 micron and larger are collected. The clean air is let out at the exhaust port of the fume extractor.

It was found that for a single shift, the filters collected the pollutants for about 3 weeks before getting choked. The cleaning cycle for the filters was established at 3 weeks. Just before getting fully choked, the filter module as well as the prefilters and postfilters are removed and cleaned using pressure water pump at about 110bar pressure. The filters are dried using a compressed air jet and repositioned inside the fume extractor. Adequate training was given to the maintenance technicians to handle the equipment. All safety features were explained and demonstrated.

Visit us: https://www.powertechindia.com

Categories Fumekiller, Soldering fume extractor Author poweradmin 0 Comments

FumeKiller® used as a Centralized Soldering Fume Extractor

Introduction:

With this project, we took an enormous stride forward in air pollution control by demonstrating the extraordinary capabilities of the FumeKiller®, our advanced soldering fume extractor. In order to address a major air quality issue, we worked closely with a client who encountered soldering fume issues at many workstations. This blog delves into the project’s complexities, describing the problem and the brilliant solution we supplied using the FumeKiller® technology.

The Challenge: Control of Fumes generated from multiple Soldering Workstations

Our customer, an established electronics manufacturer, was dealing with a serious problem: the unregulated release of soldering smoke in their production area. Soldering, a critical component of their operations, was posing health concerns to their employees and violating air quality standards due to generation of hazardous fumes. With several workstations continuously engaged in soldering processes at the same time, the customer required a complete system that could efficiently capture and control the soldering fumes.

The Solution: Centralized Fume Extraction System using FumeKiller® model FK3600EM.

Recognizing the severity of the situation, our team set out on an assignment to develop a comprehensive solution. After multiple consultations and careful investigation, we came up with the solution of deploying a centralized fume extraction system using FumeKiller® model FK3600EM as the final answer to their air pollution control needs.

  • Customized System Design: We painstakingly examined the client’s workspace layout to determine the best location for the FumeKiller® unit. This strategic arrangement enabled optimum coverage and effective extraction of soldering fumes from all workstations.
  • Powerful Extraction Technology: The FumeKiller® system boasts cutting-edge electrostatic filtration technology, which enables it to function as an effective and efficient soldering fume extractor. This feature dramatically decreases the release of pollutants into the ambient air, improvigng workplace safety and air quality.
  • Single Centralized Control: We optimized the client’s fume extraction infrastructure by supplying a single FumeKiller® machine to serve all workstations. This centralization simplified maintenance while also lowering operational costs, resulting in a cost-effective and efficient solution.
  • Customizable Features: The FumeKiller®‘s flexible design enables us to produce a specific model, in this case the FK3600EM, to meet the demand. It also allowed us to customize the extraction settings to the specific needs of each workstation. This adjustment ensured that the system was compatible with the client’s varied soldering processes.

Results and Impact:

The successful implementation of FumeKiller® yielded outstanding results for our client:

Improved Air Quality: The client noticed a significant improvement in air quality throughout their production area thanks to the robust extraction capabilities of our soldering fume extractor. Harmful soldering vapours were properly caught and filtered, resulting in a safer and healthier working environment for its staff.

Regulatory Compliance: Our solution enabled the customer to comply with stringent air quality rules, avoiding potential legal issues.

Operational Efficiency: The centralized extraction system improved the client’s workflow by eliminating the need for multiple exhaust systems. This improved productivity and resource usage.

Cost Savings: Our customer realized significant cost savings as a direct result of the unified strategy using the FumeKiller®, both in terms of equipment investment and ongoing maintenance.

Conclusion:

The successful execution of this project demonstrates our commitment to innovative and effective air pollution management technologies. By addressing our client’s soldering fume issues with a centralized extraction system, we enhanced not just their air quality and worker safety, but also their operational efficiency and environmental responsibility. The outstanding success of the FumeKiller® in this endeavour demonstrates its ability to alter industries, one clean breath at a time. If you are ready to take your air pollution management efforts to the next level, contact us today to learn about the transforming power of our fume extractors.

Visit us: https://www.powertechindia.com

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