Blog

In high-volume CNC machining environments, maintaining air quality is critical to both production efficiency and the longevity of equipment and machinery. One of the key components in ensuring optimal air quality is a mist collector. These systems capture harmful mist particles, helping maintain a clean working environment. However, when the filters in mist collectors become clogged, it can lead to unexpected downtime, reduced equipment lifespan, and even costly repairs.

This is where Vayu Mist Collectors from SFS step in, offering a solution that minimizes these risks with their built-in filter clog indicators.

Maximize Uptime in High-Volume CNC Machining

In a high-volume CNC machining setup, every second counts. An unexpected filter clog in a mist collector can bring production to a halt, causing costly and disruptive downtime. Vayu Mist Collectors are equipped with advanced filter clog indicators that allow operators to monitor the filter’s condition in real-time. These indicators alert staff when the filter is nearing saturation, enabling them to schedule cleaning or replacement during off-hours, rather than waiting for the filter to completely clog and cause an unscheduled shutdown.
By adopting this proactive approach, operators can significantly reduce the likelihood of sudden breakdowns. This not only keeps production running smoothly but also reduces the cost of emergency repairs and maximises uptime in overall operations.

Extending Equipment Life in Precision CNC Operations

Precision CNC machining relies on meticulous attention to detail, and even small disruptions in air filtration can have a significant impact. When a filter becomes clogged, it can cause the mist collector’s motor to work harder, or result in harmful particles accumulating in the air. This can lead to damage not only to the mist collector but also to CNC machines, operators and the quality of the products being manufactured.
With Vayu Mist Collectors, the filter clog indicators provide early warnings about filter performance, allowing operators to address potential issues before they escalate. This helps prevent overloading the mist collector and ensures that harmful particles don’t accumulate in the workspace. As a result, equipment lifespan is extended, product quality is maintained, and costly repairs are avoided.

Vayu Mist Collector improve overall efficiency of CNC Machines

Vayu Mist Collectors from SFS, with their built-in filter clog indicators, offer a practical solution to two of the most common challenges in CNC machining environments: unexpected downtime and equipment wear. By ensuring that filter performance is continuously monitored and addressing issues proactively, completely eliminating speculative preventive maintenance and spares replacement resulting in lowest running cost, these mist collectors help maintain smooth operations, protect valuable equipment, and improve overall efficiency.
If you’re looking to optimize your CNC machining setup and reduce unplanned maintenance, consider Vayu Mist Collectors from SFS – where innovation meets reliability.

 

 

Optimizing filter usage for mist collectors in CNC machines is essential for reducing maintenance costs, improving air quality, and ensuring the longevity of both the filters and the equipment. Here are five effective ways to optimize filter usage:

1. Choose High-Efficiency Filters

Invest in high-efficiency filters that are designed to capture fine particulates and mist effectively and filter these contaminants efficiently. These filters not only improve air quality but also last longer compared to standard filters, reducing the frequency of replacements and lowering maintenance costs while delivering consistent air quality and air flow . for example, multi-stage filtration systems designed for mist collection in CNC machines can improve filtration efficiency, ensuring fewer clogging events and longer service life.

2. Regularly Monitor and Clean Filters

Regular monitoring and cleaning of filters prevent clogging and ensure that the system operates at peak efficiency. Many mist collectors, such as the Vayu Mist Collectors from SFS, come equipped with Built-in filter clog indicators that alert operators when it’s time for maintenance. Timely cleaning or replacement can extend the life of filters and prevent any undue strain on the system, optimizing filter usage and reducing the need for frequent replacements.

3. Ensure Proper Installation and Sizing

Choosing the right size/capacity and type of mist collector filter for your CNC Machine is crucial for ensuring optimal performance. If filters are oversized or undersized, they may not operate efficiently, leading to premature wear or reduced filtration efficiency. Proper installation, including correct sealing and positioning, ensures that the filters are effectively capturing contaminants and preventing filter bypass, further optimizing usage and extending lifespan.

4. Maintain Optimal Airflow and System Efficiency

Ensuring that the mist collector is running at optimal airflow can reduce filter wear and tear and ensure efficient energy consumption. Regularly check for blockages or leaks in the ducting and make sure that the fan motor is functioning properly. Low airflow or inefficient air circulation can lead to filters working harder than necessary, leading to faster clogging and higher energy consumption. Proper maintenance of the entire mist collection system ensures that filters operate efficiently and last longer.

How SFS Helps You Achieve the Right Optimization

With 25 years of experience in industrial air filtration, SFS understands the unique needs of CNC machining operations. Our expertise allows us to help you optimize your mist collection system for maximum efficiency with long life and optimised energy consumption. We offer solutions to suit your specific needs, ensuring you get the right filters, systems, and support to achieve the best possible results while reducing maintenance costs and extending the life of your mist collector. Let us partner with you to improve air quality and ensure the longevity of your equipment and help you achieve your decarbonisation goals!

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.

Aspect	Vayu Mist Collector	Centrifuge Type Mist Collector
Operation	Uses filter media to filter the mist particles.	Uses centrifugal force to separate mist particles.
Safety and Maintenance	1. Lower upfront cost	1. Higher initial cost
	2. Simple design with fewer moving parts: Ergonomic and easy to visually check, remove the filter cassettes Fewer moving parts	2. Complex design requiring skilled maintenance personnel: Risks related to moving parts and mechanical failures.
	3. Easier to understand and maintain, reducing the need for specialized training or advanced technical skills.	3. Balancing issues causing vibration or mechanical failure may require specialized skillset for maintenance
		4. Regular monitoring of filters is required: Delays in cleaning or filter replacement can lead to clogging of filters causing unexpected downtime and requiring continuous Preventive Maintenance.
	5. Safer maintenance process: Changing filter media is easy with removable filter cassettes from a safe height.	5. Unsafe working heights to check the filter for cleaning or replacement: Adds to safety hazards when use of ladder or high-heighted benches or steps are used.

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.

 

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.