Machine tools are being pushed to run at ever increasing speeds with ever higher coolant delivery pressures, thus creating more and more coolant mist. Traditional mist collection systems simply can’t cope with these demands and allow the coolant mist to escape into the workshop atmosphere, taking other contaminants (such as fine swarf and bacteria) with it.
Any productivity gains that you expected to receive from your investment suffer as high performance machine tools are forced to run at less than optimum speed, as operators wait for the mist to settle before opening the cabin doors or reaching in to retrieve the work. Again, this is because traditional oil mist collectors cannot remove the mist quickly enough.
Clean Air ZeroMist™ Is Different
Unlike centrifugal or electrostatic systems, Zero Mist™ operates using high performance filters to ensure maximum filter life and efficiency levels in excess of 99.95%. Mist, swarf, bacteria and mold spores are trapped and the oil or emulsion can be returned to the machine tool for reuse. Maintaining a slight negative pressure in the cabin means that the doors can be opened almost immediately, without blowing contaminated air into the face of the operator.
Microscope View Of Clean Air ZeroMist™ Technology
Fundamentally Different Technology
- Removes contaminants.
- Eliminates bacteria & spores, etc.
- Returns clean air to workshop.
- Extracts contaminated air.
- Retrofit of existing coolant mist control.
- Standard replacement unit.
Stage 1 - Oil Coalescer Filters
The oil removal filters operate by collecting the oil or coolant and allowing it to drain to the base of the Clean Air Zero Mist™ unit. The filters do not “absorb” the oil, but rather coalesce it until it is heavy enough to drain.
Contaminated air passes through the filter media. As it does so, the oil particles are attracted to the oleophobic fibers. The oil droplets continue to collide with the fiber, causing the oil droplets to gain in mass. As the oil drop becomes bigger, it becomes heavy enough to fall against the airflow to the base of the Zero Mist™ unit, where it can be collected or drained straight back to the machine tool sump.
Stage 2 - Oil Removal Filters
The “scrubbed” air is then passed through a highly efficient coalescer at stage two where the coalescing process is repeated. After this second filtration stage, the air is on average 95-98% free from oil mist.
Stage 3 - HEPA Filtration
The third filtration stage is designed to completely clean the remaining air to a standard far higher than the surrounding ambient air.
Using a HEPA filter, this final stage ensures that fine, sub-micron particles (trace oil, smoke, bacteria, pollen and spores) are trapped and not allowed to return to the workshop.
HEPA filters (grade H13 EN1822) operate at 99.95% efficiency at 0.3 µm. This means that in a workshop environment, effectively all hazardous particles are trapped, ensuring only clinically clean air is returned to the workshop.