The Price Beyond the Tag: Calculating the Real Cost of Industrial Air Filters

Total cost of ownership in filter

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.

 

 Cost Component  Initial Costs (₹)  Annual Costs (₹)
 Initial Purchase Cost
 – Filter Unit Price   ₹
 – Filtration System Equipment   ₹
 Installation Costs
 – Labor Costs   ₹
 – Materials   ₹
 Additional Indirect Costs
 – Training (one-time)   ₹
 – Monitoring and Testing   ₹
 – Upgrades and Modifications (annualized)   ₹
 Operational Costs
 – Energy Consumption   ₹
 – Maintenance and Servicing   ₹
 – Filter Replacement   ₹
 Labor Costs
 – Routine Maintenance   ₹
 – Emergency Repairs   ₹
 Downtime Costs
 – Production Loss (per incident)   ₹
 – Quality Control
  Total   ₹   ₹

 

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.

Are you stuck for spares and service of imported fume extractors?

fume extractors

Stuck for spares and service of imported fume extractors?

Concerned about the high costs of imported spares? Longer lead times? Lack of local support and service?
We understand your pain!

Long wait times for spares are a typical challenge in case of imported fume extractors. The long wait times can often lead to production losses. Long-term unavailability of spares and consumables may affect laser marking or welding quality.

The vayu-L series of fume extractors from SFS is made in India. This means easy availability spares and consumables, whenever and wherever you need. vayu L laser fume extractor have earned a reputation for excellent filtration performance in Laser Marking, Laser Welding, Laser Cutting and Laser Engraving. With Nationwide network of Service Engineers, SFS is able to offer prompt support and service. Our efficient services help you to minimize downtime and keep laser related operations running seamlessly.

Made in India spares and consumables to help you reduce Total Cost of Ownership

The cost of spares and consumables over a filter’s lifetime could be significant. SFS has therefore put in R&D effort to design, engineer and develop each component in India. As compared to the lead time and relatively high costs of imported spares, SFS spares bring you significant savings on Total Cost of Ownership.

Why Choose SFS:

  • Local Presence, Global Expertise: Benefit from a Nationwide reach with installations in 170+ industrial clusters.
  • Quick Turnaround: Minimise downtime with prompt support from experienced professionals.
  • Lowest Total Cost of Ownership: Made in India, high-quality, durable spares and consumables at optimal costs

In case you are facing a challenges of long wait times and high costs of imported spares, switch to vayu-L from SFS. Get in touch with us at cleanair@sfspl.co.in for more details.

 

Making Gear Manufacturing Cleaner and Safer with SFS Advanced Filtration Solutions.

Air filtration for gear manufacturers

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

SFS has proven filtration solutions for all critical processes in gear manufacturing including:
  • Billet Heating
  • Hot Forging
  • Bar Cutting
  • Rough Machining
  • Gear Cutting
  • Profile Grinding
  • Heat Treatment
  • Washing
  • Shot Blasting
  • Laser Marking
  • Anti Rust Spraying

 

India’s leading Gear manufacturers, exporters and OEMs trust SFS dust, mist, smoke and fume filters for their gear manufacturing processes.
Know why clean air is important – https://sfspl.co.in/what-is-clean-air/

 

At SFS, we are committed to unleashing the potential of clean and efficient gear manufacturing.
If dust, mist, fume, smoke in gear manufacturing worries you….connect with us – https://sfspl.co.in/contact-us/

Unlocking Industrial Efficiency Insights on Dust, Mist, Fume and Smoke Extraction in Manufacturing Facilities

Dust, Mist, Fume and Smoke Extraction in Manufacturing Facilities

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

In your pursuit of manufacturing excellence, it’s crucial to recognize that the real asset isn’t just the machinery but the workforce operating it. A healthy and safe working environment directly contributes to the well-being and productivity of the employees. Industrial air filters, by efficiently removing harmful airborne particles, create a healthier atmosphere that fosters employee well-being, reduces absenteeism, and enhances overall productivity.

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

Creating a manufacturing facility that meets global standards goes beyond the specifications of the machines; it extends to the environment itself. A litmus test for the excellence of a facility is whether a client from Europe or the US could confidently walk into the shop floor, even in the absence of the Owner or Plant Manager. The key here lies in the effectiveness of the filtration systems. Clean air not only signifies a commitment to quality but also instills confidence in clients regarding the integrity of the manufacturing processes.

 

As Indian manufacturers continue to evolve and expand globally, the role of industrial air filters becomes increasingly central to their new facilities. Beyond meeting regulatory requirements, investing in effective filtration solutions becomes a strategic move towards creating world-class manufacturing facilities that not only house cutting-edge machines but also prioritize a clean, healthy, and impressive working environment. After all, in the pursuit of excellence, every breath counts.

 

SFS has helped several manufacturers to transform and establish a world-class environment in their facilities. Want to know more? Get in touch with our experts at cleanair@sfspl.co.in

Laser Fume Extractor FAQs

Laser Fume Extractor FAQs

In recent years, almost every manufacturing industry has witnessed a significant surge in the use of laser technology for marking, welding, and engraving applications. Laser systems have become indispensable tools across various sectors due to their unmatched precision and versatility. From marking serial numbers on manufactured goods to intricately engraving detailed designs, and from laser welding micro-components to larger industrial tasks, the applications of laser technology continue to expand. This growing trend reflects a fundamental shift in how industries approach these processes, highlighting the need for efficient and tailored fume extraction solutions.

As the demand for laser-powered applications continues to rise, ensuring a clean and safe working environment through effective fume extraction becomes a crucial consideration. Let’s explore the essential aspects of selecting a laser fume extraction system to complement the increasing prevalence of laser-based applications.

What is a laser fume extraction system, and why is it necessary in laser applications?

A laser fume extraction system is designed to capture and filter airborne contaminants, such as fumes and particulates, generated during laser processes. It helps maintain a clean and safe working environment.

What types of contaminants can laser fume extraction systems capture?

These systems are designed to capture various contaminants, including laser-generated fumes and particulates, depending on the materials being processed.

How does a laser fume extraction system work?

Laser fume extraction systems typically use a combination of fan and filters to capture and filter out fumes and particles produced during laser cutting, engraving, or marking processes.

What are the key components of a laser fume extraction system?

A typical system includes a capture hood, ductwork, a filtration unit with specific filters for laser-generated contaminants, and a fan or blower to capture and extract the pollutants generated during the process.

Can a laser fume extraction system be used with different types of lasers and materials?

Compatibility with different laser types and materials is crucial. Ensuring that the system can effectively capture and filter the specific contaminants generated in your laser processes is the key to its effectiveness.

What types of filters are used in laser fume extraction systems, and how often do they need to be replaced?

Different filters are designed to capture specific contaminants. Understanding the types of filters used and their replacement frequency is essential for ongoing maintenance. Specific filters for odour removal can be added on request. Frequency of filter replacement depends on the laser process and material used.

Is the system designed to handle high volumes of air and contaminants generated during intensive laser applications?

It is very important that manufacturers assess and understand the air volume and contaminant characteristics before purchasing the laser fume extractor. Depending on your laser processes, it’s important to choose a system with the capacity to handle the volume of air and contaminants produced.

What safety features are included in the laser fume extraction system?

Safety features may include alarms for filter replacement, airflow monitoring, and other indicators to ensure the system is operating effectively and safely.

Can the system be integrated with existing laser equipment or workstations?

Integration capabilities are important for seamless operation. Ensure that the system can be easily integrated into your current laser setup. Consider size of the systems, mounting options, portability requirements and hood designs for easy integrations.

What is the energy consumption of the laser fume extraction system?

Understanding the energy consumption helps assess the operational costs of the system over time. Look for energy-efficient options that align with your sustainability goals and to reduce the Total Cost of Ownership.

Does the manufacturer provide training and support for the installation and operation of the system?

Adequate training and ongoing support are essential. Ensure the filter manufacturer provides training for system installation, operation, and maintenance.

What is the warranty coverage for the laser fume extraction system, and what does it include?

Inquire about the warranty terms, including duration and coverage. Understanding the warranty details provides assurance and clarity on potential issues that may arise after purchase.

These questions can guide your decision-making process when evaluating and purchasing a laser fume extraction system for your specific applications.

What is Clean Air?

What is Clean Air

Breathing Easy in Manufacturing: Navigating the Depths of Clean Air

The importance of clean air in manufacturing is the cornerstone for both human health and the efficiency of industrial assets. Let’s delve deeper into the nuances of clean air, specifically within the context of manufacturing, where dust, mist, fumes, and smoke filtration play a pivotal role in creating a truly healthy and productive workspace.

Why Clean Air in Your Factory Matters?

Clean air in manufacturing is more than just the absence of visible particles; it’s a meticulous process achieved through effective filtration. The quality of air directly impacts the well-being of your workforce by reducing the risk of respiratory issues, promoting a comfortable work environment, and enhancing overall job satisfaction. Moreover, it safeguards the performance and lifespan of your industrial equipment, mitigating the potential adverse effects of airborne contaminants.

Infographic for What is Clean Air

What is Clean Air in Manufacturing?

In the manufacturing context, clean air involves the meticulous removal of various pollutants, including dust, mist, fumes, and smoke. It’s an environment where the concentration of these contaminants is minimized, creating a workspace that not only complies with safety standards but also fosters optimal operational conditions.

Symptoms of Poor Air Quality in Your Factory

Identifying poor air quality in manufacturing involves recognizing the specific symptoms associated with different pollutants. Persistent coughing may indicate exposure to airborne dust, while eye irritation could be a result of mist or smoke. Fatigue and headaches can be linked to poor ventilation and fume extraction.

Effects of Poor Air Quality on Your Assets

The impact of poor air quality extends beyond human health to the very core of your manufacturing assets. Dust, mist, fumes, and smoke can accumulate on machinery, leading to increased maintenance costs, reduced operational efficiency, and a higher likelihood of unexpected breakdowns. Clean air, achieved through robust filtration systems, acts as a shield against these detrimental effects.

Why is Monitoring PM Levels Essential for Assessing Clean Air Quality in Manufacturing?

Monitoring Particulate Matter (PM) levels is crucial for gauging clean air quality in manufacturing. PM, especially the ultrafine PM1 particles with a diameter of 1 micron or less, plays a significant role in both human health and industrial asset maintenance. These microscopic particles, often generated in manufacturing processes, can impact respiratory health and accumulate on machinery. By measuring PM levels, we gain insights into the effectiveness of our filtration systems, ensuring that the air quality remains optimal. It’s not just a numerical value; it’s a direct indicator of the health of the air in the manufacturing environment, vital for both the well-being of the workforce and the longevity of valuable assets.

Understanding PM1 and Filtration Challenges

Particulate Matter 1 (PM1) represents particles with a diameter of 1 micron or less. These ultrafine particles pose a unique challenge as they are small enough to bypass standard filtration systems. In manufacturing, where various processes generate fine particulates, including welding fumes and microscopic dust, effective filtration becomes imperative. Choosing advanced filtration solutions capable of capturing PM1 and smaller sized particles ensures a comprehensive approach to clean air.

How to Improve Air Quality in Your Facility: A Filtration Focus

Improving air quality in manufacturing involves a meticulous approach to filtration. Investing in high-efficiency air filtration systems tailored to the specific contaminants generated in your processes is paramount. Consider advanced technologies such as Dust Collectors, Mist Collectors, Electrostatic Precipitators, Fume Extractors for comprehensive coverage. Regular maintenance and monitoring ensure that these systems continue to operate at peak efficiency.

The pursuit of clean air in manufacturing requires a multidimensional approach, with a keen focus on dust, mist, fume, and smoke filtration. This approach not only aligns with safety standards but also cultivates an environment conducive to human health and the sustained efficiency of industrial assets.

As manufacturing continues to evolve, integrating advanced filtration technologies becomes not just a necessity but a strategic investment in the well-being and longevity of both your workforce and your machinery. In the symphony of manufacturing, clean air orchestrates a harmonious workplace, ensuring that every breath taken is one of health and productivity.

Grinding Dust Collector – 5 Challenges for filtration

Grinding Dust Collector - 5 Challenges for filtration

The grinding process stands as a cornerstone of precision and productivity. However, this essential process brings with it a formidable adversary: grinding dust collector. Beyond polluting nature, grinding dust presents a series of complex challenges that demand innovative solutions. The remarkably fine particles it generates, the high volumes it accumulates, and its abrasive nature create hurdles for conventional filtration systems. Additionally, the diverse mix of materials being ground and the potential health hazards posed by airborne contaminants further compound the filtration dilemma.

Grinding Dust Collector – Challenges for filtration

1. Fine Particle Size:

Grinding processes generate extremely fine particles that are difficult to capture using conventional filtration methods. These tiny particles can remain suspended in the air for extended periods, posing a significant health risk to workers and contaminating the environment.

2. High Dust Load:

Grinding operations can generate a high volume of dust in a short amount of time. This heavy dust load can overwhelm standard filtration systems, causing filters to clog quickly and reducing their efficiency.

3. Abrasive Nature:

Grinding dust is often abrasive in nature due to the materials being ground. This abrasiveness can cause rapid wear and damage to filtration equipment, leading to increased maintenance and replacement costs.

4. Mix of Materials:

Workshops frequently handle a variety of materials with different properties during grinding operations. This diverse mix of materials presents a challenge for filtration, as filters need to be effective across a range of particle sizes.

5. Airborne Health Hazards:

Grinding dust can contain hazardous substances such as metals, chemical compounds, and allergens. Without proper filtration, these airborne pollutants can pose serious health risks to workers, leading to respiratory issues and other long-term health problems.

6. Safety Hazard:

Inhaling the dust may cause respiratory issues and eye irritation, posing health risks to workers. Accumulated dust on floors can create slip and fall hazards, while combustible dust can increase the risk of fires. Electrical equipment can malfunction, and visibility may be compromised, heightening the chances of accidents. Additionally, product contamination and regulatory non-compliance can result from unfiltered dust. Ensuring proper dust filtration is crucial for maintaining worker safety, preventing equipment damage, and adhering to workplace regulations.

In the face of these challenges, the quest for effective grinding dust filtration becomes more critical than ever. SFS offers a complete solution for overcoming these challenges and provides the required specialized filtration systems that are designed to handle the unique characteristics of grinding dust. High-performance dust collectors with efficient filtration mechanisms, self-cleaning features, and the ability to handle high dust loads are crucial for effectively addressing these challenges and maintaining a safe and productive working environment. Get in touch with SFS experts to discuss the challenges in your grinding process to develop the right solution. Write an email to cleanair@sfspl.co.in

Subscribe Now