When a Midwestern bearing manufacturer installed its centralized collection system many years ago, it was state of the art, top of t

Headquartered in a 140,000-square-foot facility in Columbia City, Indiana, 80/20® Inc. is the one-stop resource for more than 6,500 aluminum modular framing systems and accessories. Known for the first Industrial Erector Set®, 80/20 Inc. designs, manufactures and assembles standard and custom-built solutions for machine frames, guarding, enclosures, displays, workstations and more.

To create the range of 80/20 solutions, T-slotted aluminum frames are custom cut on-site using high-speed saws and routers. During the routing process, dust, mist and aluminum by-products, called turnings, are generated. These need to be captured and filtered into the scrap aluminum recycling stream. “We immediately contacted Donaldson Torit,” said Mike Downam, maintenance facility manager at 80/20. “We needed a filtration solution that included a vacuum strong enough to pick up the turnings and collect the mist generated from the water-soluble coolant used to cool down the cutting tools during the routing process. If not removed quickly, the turnings will damage the frame, not to mention the mess the dust and mist can leave on the shop floor.”

The Donaldson Torit Solution

Two Donaldson Torit solutions were combined to meet 80/20’s filtration needs: A Model 24 Cyclone Dust Collector was installed to capture the aluminum turnings, and a WSO 25-2 Mist Collector to remove the water-soluble mist.

The Cyclone Dust Collector is a mechanical separator that uses centrifugal force to remove large and high-volume particulate formed in industrial manufacturing. For 80/20, an abrasion-resistant coating was put on the interior of the Cyclone to protect it as the turnings were removed. The collector’s legs were also extended to accommodate a Donaldson® Torit® 10AN rotary valve.

Uncollected coolant can cause slippery floors and collect on machines, walls and ceilings, creating an unpleasant, high-maintenance working environment. To remove the mist generated from water-soluble coolant, a WSO Mist Collector with a water-soluble filter was ducted into the 80/20 central system. The versatile WSO provides three filtering solutions for the three mist categories: water-soluble coolants, straight oil and oily smoke. It can be modified with a simple filter change, leading to leaner operations, cost savings and a cleaner plant floor. The WSO also employs Donaldson’s revolutionary Synteq XP™ Media Technology engineered to provide superior draining, which results in lower pressure drop and longer filter life.

he line – a real performer in its day. But with the passing of time, innovation in in-plant filtration technology had outpaced the efficiency of the now behemoth monster, which includes miles of ductwork that hangs from the plant’s ceiling. It was time for a change. Enter Donaldson Torit®.

“The existing centralized system was inefficient to operate, and this resulted in excessive operating costs,” said Dave Godlevske, District Manager at Donaldson Torit®, a designer and manufacturer of in-plant air filtration and pollution control systems, replacement filters and products that reduce dust, fume, and mist contaminants in the workplace. “Our customer needed a filtration solution that would capture mist during the wet manufacturing process and recycle it back through the system. It had to be energy efficient and easy to maintain.” Donaldson® Torit® mounted a WSO Mist Collector on each of 20 machines on the manufacturing line. 

The Donaldson Torit® WSO Mist Collector provides three filtering solutions for the three mist categories: water-soluble coolants, straight oil, and oily smoke – an ideal solution for the wet manufacturing processes used in bearing manufacturing. As coolant is sprayed on hot metal during the bearing forming process, mist is generated that can be harmful to the operator. The WSO Mist Collector captures the mist using a cross-flow filter manufactured with Synteq XP™ filter media. This proprietary media is engineered for superior drainage, resulting in lower pressure drop and longer filter life. Synteq XP media blends small and large fibers with a proprietary, resin-free bonding system. Smaller fibers are scientifically proven to increase efficiency while larger ones provide structural support and clear drain channels. The proprietary bonding system stabilizes pore structure for optimum performance.

By installing a dedicated WSO for each machine on the production line, the bearing manufacturer has realized a host of operating efficiencies:

• A reduction in energy usage as only those machines being operated require the use of the WSO collection system;
• Line operators can monitor filter maintenance by the prominently placed differential pressure gauge thereby extending filter life; and
• Simplified servicing meant less maintenance time and cost.

Since installing the initial 20 WSO mist collectors, an additional 20 collectors have been installed on the bearing manufacturing line with plans for more in the future. “We delivered on our promise of operating efficiency and reduced maintenance cost,” concluded Godlevske. “As additional WSOs are installed, we know our customer will continue to run a leaner manufacturing facility.”