The basic concept of coalescing fiber beds is simple. The oil or emulsion wicks on tiny strands of fiber inside the filter (imagine water wicking on Gore-Tex) and coalesces into larger droplets. These droplets fall to the basin at the bottom of the unit and can be either drained or pumped out.
In simpler terms, the Clean Air America coalescing fiber bed is “catch and release” versus traditional mist collectors which are designed to cash and hold the mist. The result is an expectation of over a year of filter life and the ability to recycle your coolants.
Filter Life: The coalescing fiber bed technology allows for over a year of filter life in most applications from machining to tougher ones like cold heading or swiss turn.
Recycle Your Coolant: Because the mist and/or oil smoke is captured and released, you can re-use your coolant.
Clean Air: The final stage of filtration is a HEPA which is 99.97% efficient down to .3 microns (the width of a human hair is about 70 microns). The result is a conversion of your dense and oily smoke into cleaner air than you are breathing right now.
Plant Cleanliness: The oil or coolant that escapes from your process needs to collect somewhere. Usually it is on your walls, ceilings, and floors. Proper collection and filtration will help you avoid unsafe conditions and maintain a clean environment you are proud to show off.
Health Effects: Coolants coming off machining processes are often sub-micron, the average width of a human hair is 70 microns. The human body (your lungs) is not designed to filter sub-micron particulate, meaning these chemicals have easy access to your blood stream which can cause serious long term health effects.
– Grinding (water-based & synthetic coolants)
– Turning (water-based & synthetic coolants)
– PrintMilling (water-based & synthetic coolants)
– Machining (water-based & synthetic coolants) with moderate spindle speeds
– Designed for 24/7 operations, these units have the longest filter life in the industry!
– Self-draining filters
– Optional VFD packages for energy savings
– Heavy-duty cabinet construction made in the USA
– Maximum coolant reclaim
– Customization with modular construction
– Custom control panel options include UL/CSA rated magnetic IEC/NEMA motor starter packages, VFD Smart Panels™ and optional PLC packages that allow for complete monitoring of voltage, amperage, filter conditions, alarm conditions, and additional parameters.
– Configurations available with CFM up to 28,800!
– Eliminates coolant mist (neat oil or emulsion)
– With extremely low PM you can install and relax, checking gauges periodically
– Designed to work 24/7 even in high demand applications
– Simple and low cost to install
– Removes harmful particles including bacteria
– Main filter life can exceed 2 years
– Reuse separated oil
– Speeds up the production process
– Can be connected to several machines
– Reduces power consumption
– Oil mist collects on floors, walls, and machines creating a slippery, unsafe working area
– The oil smoke produced is hazardous to one’s health, OSHA regulated
– The oil that drops from the filter can be reused
– Longest filter life (3-5 year average), meaning less filter changes vs other collection systems
Health and safety issues are being taken very seriously by a growing number of companies as OSHA, International, and industry standards increase. Many large US manufacturers are planning ahead and adopting European exposure limits as a global standard for their entire company and are exceeding OSHA Standards. To meet these standards companies must implement a highly efficient oil mist and oil smoke filtration system to filter out the particles.The exposure limits these companies are targeting range from .02 – 1 mg/m3 depending on company policy, well below the 5 mg/m3 standard set by OSHA. Older mist collector technology simply cannot provide these higher requirements and need a high tech and high efficiency unit to get reach these exposure limits.
Clean Air American can take a single module, such as the OM 2400 in this example, and combine multiple units together width-wise to meet the larger flow requirements of certain projects.