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In many manufacturing environments, with processes like Electric Discharge Machining (EDMs), soldering, laser marking or similar operations, the presence of low-volume fume or smoke is often overlooked. There’s a common mindset that if the fumes aren’t dense or immediately overpowering, they aren’t a serious concern. This belief is reinforced by the fact that these fumes, while sometimes causing mild irritations or unpleasant smells, don’t seem to have an immediate impact on health or the quality of work on the shop floor.

However, this mindset is misguided.

The truth is, even low levels of fumes and smoke contain harmful particulates that, over time, can lead to serious health problems. It’s easy to dismiss a minor irritation as insignificant, but this exposure is no less than slow poisoning. The cumulative effect of inhaling these toxic fumes or smoke day in and day out can lead to respiratory issues, illnesses, and other long-term health problems.

The need to change this mindset is urgent.

Ensuring clean air in the workplace is about valuing health and safety. Proactive measures, such as use of fume extraction systems, are essential in preventing the long-term damage that these seemingly minor irritants can cause.

How to remove the unpleasant smell from low volume fumes or smoke?

SFS’s team often gets queries on how to remove the unpleasant odor from the low-volume fumes or smoke on the shopfloor.

To effectively address the issue of unpleasant odors from low-volume fumes or smoke, it’s essential to focus on both odor elimination and overall air quality. SFS offers advanced fume extraction systems designed to not only capture and filter out harmful particulates but also neutralize unpleasant smells. By implementing these solutions, you can ensure a safer, more comfortable work environment, protecting both the health of your employees and the integrity of your operations. Prioritizing clean air is an investment in your team’s well-being and the long-term success of your business.

To ensure efficient and effective fume extraction in processes such as EDM, Laser Marking, Soldering etc. do get in touch with our experts.

Decarbonisation is a top priority for the manufacturing sector, especially in light of increasing carbon taxes. Original Equipment Manufacturers (OEMs) are now urging their Tier I and Tier II vendors to take proactive steps in driving decarbonisation initiatives, complete with specific targets to achieve. Among the various strategies being considered, improving the energy efficiency of equipment stands out as a cost-effective and impactful option. One such equipment upgrade that is gaining traction is the replacement of existing oil mist collectors on CNC machines.

The Economics of Oil Mist Collectors

The energy bills for operating traditional mist collectors can range from ₹50,000 to ₹150,000 annually, which is almost equivalent to the initial cost of the oil mist collector itself. By replacing these with more energy-efficient models, significant savings can be realized. For instance, if a new oil mist collector can reduce energy consumption by 30%, the payback period for this investment is less than three years. Such investments are not only light on the pocket but also contribute substantially to watt savings, thus aiding in achieving decarbonisation goals.

Why Choose SFS’s Vayu Mist Collector?

This is where SFS’s Vayu Mist Collector brings in cost savings for you. With up to 30% lower energy consumption compared to the centrifuge-type mist collectors, and significantly reduced spare parts and maintenance costs, Vayu has proven to be a high-impact solution for decarbonisation. The benefits of upgrading to Vayu are clear: reduced energy bills, lower operational costs, and a smaller carbon footprint.

A Practical Example

Consider a manufacturing shop floor with hundreds of CNC machines, each equipped with centrifuge type mist collectors. By replacing these with Vayu mist collectors, the energy savings can be substantial. Customers who have replaced existing centrifuge mist collectors with Vayu oil mist collectors have gained significant energy savings every month.

Take the Next Step

If you want to replace centrifuge type mist collectors on the shopfloor and explore how much you can save in energy costs, speak to our experts. Replacing existing filters with SFS’s Vayu Mist Collector could be the game-changer your facility needs.

Got doubts? Get in touch with our experts at cleanair@sfspl.co.in and start your journey towards a more sustainable and cost-efficient operation.

Poor quality of soldering due to fumes in electrical wire harness manufacturing can lead to several issues that may impact the overall functionality and reliability of the wire harnesses.

Some specific issues caused by soldering fumes include:

1. Incomplete or Cold Solder Joints:

Soldering fumes can obstruct the soldering process, leading to incomplete or “cold” solder joints. Cold solder joints have poor electrical conductivity and mechanical strength, causing intermittent connections or complete failures.

2. Solder Bridging:

Excessive fumes can create an uneven distribution of solder, resulting in solder bridging between adjacent electrical connections. This can cause short circuits and malfunctioning of the wire harness.

3. Solder Splatter:

Fumes can lead to uneven heating of the solder, causing splatter that may land on adjacent electrical components or connections. This can create short circuits and damage electronic components.

4. Corrosion:

Residue from soldering fumes, such as flux or other contaminants, can cause corrosion on the solder joints or nearby components. Corrosion weakens the connections and can lead to electrical failures over time.

5. Reduced Adhesion:

Soldering fumes can interfere with the adhesion of solder to the wire strands or terminal surfaces, resulting in weak connections that may break under stress.

6. Contamination of Insulation:

Soldering fumes may deposit residue on wire insulation, compromising its dielectric properties and leading to insulation breakdown or reduced performance.

7. Electromagnetic Interference (EMI):

Poorly soldered connections due to fumes can increase the impedance of the wire harness, leading to EMI issues and signal interference in sensitive electronic systems.

8. Reduced Electrical Conductivity:

Incomplete soldering due to fumes can lead to high electrical resistance at the joints, affecting the overall electrical conductivity of the wire harness.

9. Reliability Issues:

Poor soldering quality caused by fumes can result in premature failures or performance issues in the wire harness, leading to increased maintenance costs and reduced product reliability.

10. Safety Hazards:

In extreme cases, poor soldering due to fumes can create safety hazards, such as short circuits or sparks, which may lead to electrical fires or accidents.

To avoid these issues, it is crucial to implement effective fume extraction systems and provide proper training to soldering operators. Maintaining a clean and fume-free work environment ensures high-quality soldering and reliable electrical wire harnesses.

SFS has helped several electronics components manufacturers to overcome faults and reduce the risks related to soldering fumes. SFS’s Solutions are well proven to provide highly effective fume filtration for single or multiple soldering stations. Experts from SFS are always available to assist you at every step, from selecting the right filter to designing and implementing of fume filtration System. The experts have a deep understanding of the soldering process and help you resolve technical issues, and meet all the health and compliance standards required for soldering.

If you suspect that the fumes are affecting the soldering quality in your components, or impacting health of workers, do get in touch with us at cleanair@sfspl.co.in

Mist Collector : Which is the easiest and safest to maintain?

Vayu from SFS is a media barrier type mist collector that stands out for being easier and safer to maintain. The lower upfront costs, simple design with fewer moving parts, and predictable maintenance schedule make vayu mist collector accessible and manageable for several use cases in the manufacturing industry. Additionally, the maintenance process for media filters is safer, as it avoids the complex mechanical hazards associated with centrifugal systems. This makes media barrier type filters a practical choice for maintaining clean, efficient, and safe industrial environments.

Filter Clog Indicator in vayu mist collector from SFS makes the job even easier

Timely Filter Change Alerts: Filter clog indicators in vayu mist collectors provide real-time feedback on the condition of the filters, alerting maintenance personnel when they require maintenance. This proactive notification allows for timely maintenance interventions, preventing potential downtime or performance degradation due to clogged filters and eliminates the need for Preventive Maintenance.

Optimized Performance: Due to the built in filter clog signal, the mist collector can be run at optimal airflow and filtration efficiency.  With vayu’s filter clog indicator, operators can ensure that the mist collector operates at peak performance levels, maximizing its effectiveness in capturing airborne contaminants.

Improved Safety and Compliance: Maintaining clean air in industrial environments is essential for ensuring worker safety and regulatory compliance. The filter clog indicator helps to ensure compliance to air quality standards with assurance that the mist collector operates efficiently, effectively capturing contaminants before they can pose health risks to personnel or environmental concerns. This proactive approach to maintenance contributes to a safer work environment and helps businesses meet their compliance obligations.

Our experts are always available to solve your queries and provide support with the most optimized Solution for your application. Drop an email to cleanair@sfspl.co.in to schedule your appointment.

When considering industrial air filters, such as those for dust, mist, fume, and smoke, it’s crucial to evaluate the total cost of ownership (TCO) rather than just the initial costs. The TCO encompasses not only the purchase price but also installation, energy consumption, maintenance, filter replacements, labor, downtime, disposal, and environmental compliance costs. This comprehensive approach ensures a more accurate understanding of the long-term financial impact, helping businesses avoid unexpected expenses and operational disruptions. By focusing on the TCO, companies can make informed decisions that balance cost-efficiency with optimal performance, ultimately ensuring a safer and more sustainable work environment.

Detailed Breakdown of Total Cost of Ownership in Industrial Air Filters

The total cost of ownership (TCO) for industrial air filters encompasses various factors beyond the initial purchase price. Understanding these components can help businesses make informed decisions and manage long-term costs effectively. Here’s a detailed breakdown:

1. Initial Purchase Cost:

• Filter Unit Price: The upfront cost of purchasing the filters themselves, which can vary based on the type (pre-filters, HEPA filters, activated carbon filters) and quality.
• Filtration System Equipment: The cost of the filtration system, including housing units, additional fans, ductwork, and automation or control systems.

2. Installation Costs:

• Labor Costs: Expenses associated with hiring technicians to install the filtration system.
• Materials: Costs for additional materials required during installation, such as mounting brackets, seals, and electrical wiring.

3. Additional Indirect Costs:

• Training: Costs for training staff to operate and maintain the filtration system properly.
• Monitoring and Testing: Expenses for regular air quality monitoring and testing to ensure the system is performing effectively.
• Upgrades and Modifications: Periodic upgrades or modifications to improve system performance or adapt to changing needs.

4. Operational Costs:

• Energy Consumption: The electricity required to operate the filtration system. High-efficiency units may have higher upfront costs but lower energy consumption.
• Maintenance and Servicing: Regular maintenance tasks such as cleaning, inspections, and servicing by professionals to ensure optimal performance.
• Filter Replacement: Periodic replacement of filters, including pre-filters, HEPA filters, and activated carbon filters. The frequency of replacement depends on the filter type, usage, and environmental conditions.

5. Labor Costs:

• Routine Maintenance: Costs for the time spent by in-house staff or contracted technicians on regular maintenance activities.
• Emergency Repairs: Expenses for labor and materials required to address unexpected breakdowns or system failures.

6. Downtime Costs:

• Production Loss: Financial losses incurred due to reduced or halted production during maintenance or repair activities.
• Quality Control: Costs related to managing any quality issues arising from suboptimal filtration, such as contamination of products or workspaces.

Explanation

• First-Year Total Cost: ₹ (initial costs) + ₹ (annual costs) = ₹
• Subsequent Annual Costs: ₹

The table provides a clear breakdown of the TCO for industrial air filters in INR, enabling better financial planning and decision-making. By understanding these costs, businesses can ensure they invest wisely in maintaining air quality standards while managing expenses effectively.

If you need assistance for calculating TCO of filters for your specific applications, we can help! SFS is committed to lowest TCO across your applications to filter dust, mist, fume or smoke.

Do get in touch with us at cleanair@sfspl.co.in to make your selection on the prudent TCO framework.

Maintaining productive work environment in gear manufacturing is not an easy task. At Span Filtration Systems, we know the unique challenges faced by gear manufacturers. Our industrial filtration solutions deliver clean air at workplace and efficiency at every step in gear manufacturing.

Spotting the challenges – Dust, Mist, Smoke, Fume Filtration in gear manufacturing

From bar cutting to billet heating and hot forging, each stage presents its own set of obstacles. Identifying these challenges is the first step toward achieving a cleaner and more efficient gear manufacturing process.

SFS offers advanced range of industrial filters and machines designed to address specific challenges at various stages of gear manufacturing.

• Vayu mist collectors are engineered to effectively remove oil mist and coolant fumes generated during bar cutting, ensuring a safer and cleaner workplace for your operators.
• For the filtration of smoke during billet heating, our ESP purasmoke system is the solution, capturing and eliminating smoke to create a healthier environment while maintaining high-quality production standards.
• puradust dust collector efficiently handles the dust generated during machining, and grinding contributing to a dust-free and clean working environment.

Partner with SFS for all your filtration needs in gear manufacturing

• Billet Heating
• Hot Forging
• Bar Cutting
• Rough Machining
• Gear Cutting
• Profile Grinding
• Heat Treatment
• Washing
• Shot Blasting
• Laser Marking
• Anti Rust Spraying

Indian industries are embracing world-class machinery and systems for global exports. The aspiration is to create top-notch facilities, second to no one in the world. One integral element that often flies under the radar but plays a pivotal role in achieving excellence is the deployment of industrial air filters such as Industrial dust, mist, fume and smoke extractors.

World class infrastructure and world-class environment are two different things!

Investing in world-class machinery is undoubtedly a crucial step toward achieving manufacturing excellence, but it’s equally vital to recognize the distinction between infrastructure and environment. While cutting-edge machines contribute to infrastructure, maintaining a clean air in the factory environment requires a holistic approach that includes effective filtration systems for industrial dust, mist, fume and smoke extraction. The air quality in manufacturing spaces directly impacts the efficiency of operations, product quality, and the overall well-being of the workforce.

High precision needs the removal of process pollutants such as dust, mist, fume, and smoke extraction

Precision manufacturing demands a meticulous approach not just in machine calibration but in the entire process environment. Microscopic pollutants like dust, mist, fume, and smoke might seem harmless, but their presence can jeopardize the precision of machinery and the quality of the final product. Industrial air filters act as silent guardians, ensuring that these pollutants are effectively removed, thereby safeguarding the precision of the manufacturing process.

A healthy workforce (and not just the machines they operate) is your real asset

The litmus test – can my European or US-based client walk into my shop floor even when you are not around?