Air filtration

Oil mist separator, oil mist filter

Given the high speed of our production and process in the metalworking industry, the cooling and lubricating of the workpiece or tool as well as the removal of chips is imperative and necessary. We use specially-developed emulsions, cooling lubricants and oils.The reasons for the formation of the oil mist include the rapid rotational movements in the machining process, which causes the oil to be sprayed around in the workshop. Fine oil droplets form, which connect with the ambient air. (under certain circumstances, this can even result in an ignitable oil-air mixture!)

The workpiece is subject to high thermal stresses during the machining process. By cooling the workpiece, the oil evaporates to oil vapour or oil dust and at the same time a small part of the oil burns up. It also creates oil smoke.

Should the oil mist get into the air, over time an oil film will settle on all the items in the room.

The particle size of oil vapour or oil dust is less than 1 micron, and can be inhaled but cannot be coughed out. These particles settle in the alveoli and thus pose an increased risk of cancer.

The oil smoke causes an additional odour problem.

E-filters can provide a solution to this problem. Electrostatic filters and electrostatic oil mist separators can filter out up to 99% of oil particles. Electrostatic air filters are particularly suitable for the separation of very small particles (separation up to 0.01μm) and provide a separation efficiency of up to 99%.

The filters of the elstar series are suitable for this purpose.

Emulsion mist separator- Cooling lubricant mist separator

Emulsion is a mixed liquid consisting of at least two immiscible components with no visible segregation. Apart from the pharmaceutical industry (creams, ointments, etc.), emulsions are also used in the metalworking industry.

Since metal processing usually involves high process speeds, it is necessary to cool and lubricate the workpiece or the tool and to remove any shavings that may have accumulated. Emulsions which are specially developed for the respective material, also referred to as cooling lubricants (KSS), are used. These KSS fluids are swirled around very fast as part of the processing and partly burned up by the high temperatures.

This creates a dangerous and harmful cooling lubricant mist or emulsion mist (KSS mist). This fine mist, with a droplet size smaller than 2.5μm to 2.0μm, settles in the machining workshop, contaminates your other equipment and results in an increased risk of fire.

The health hazards are even more dangerous:

• increased danger of slipping
• irritation of the mucous membranes, skin and eyes
• Small particles settle in the alveoli and cannot be coughed out. (Increased risk of cancer, see VDMA cooling lubricants)

The solution comes in the form of emulsion mist separators or cooling lubricant mist separators.

Electrostatic air filters are particularly suitable for the separation of very small particles (separation up to 0.01μm) and provide a separation efficiency of up to 99%.

Emulsion mist can be filtered out of the air very effectively with our elstar or mestar devices.

We also recommend using a pre-separator for optimal results and to extend the cleaning interval for KSS. The KSS filtered from the air can be fed back into the machining process.

The contaminated KSS is generally reprocessed by means of a suitable filter system.

For more information on wet filtration see filter fleece/wet filtration.

An optimally-cleaned KSS not only reduces tool wear but also improves workpiece surface finish.

With minimum quantity lubrication, only small amounts of cooling lubricants are used.

The oil-air mixture should prevent or reduce frictional heat by means of optimal lubrication. The main heat is to be dissipated via the tool and the shavings. The coolant lubricant must be applied cleanly and fed to the correct location in the machining process. Minimum quantity lubrication is when less than 20 ml of cooling lubricant is used during a machining process.

Benefits of MQL includes low disposal load, long service lives and, unlike with wet processing, the dry chips can be further processed as recycling material. The aerosol vapours produced during minimum quantity lubrication must be filtered accordingly.


Our elstar and mestar models are particularly well-suited for this.

Soldering smoke and Soldering fumes

The cohesive joining of materials is called soldering. Soldering can be divided into soft and hard soldering. Soft soldering involves solders with a melting temperature below 450 °C and hard soldering involves solders with a melting temperature above 450 °C.
Soldering fumes or soldering vapour is produced during soldering irrespective of soldering methods or the temperature range. These vapours can be very toxic, depending on the flux or soldering material used. The constituents of the soldering fumes are mostly lead, cadmium or other heavy metals. Rosin is used in the flux. It burns up completely depending on the temperature. All these substances make the soldering fumes especially harmful for your health.

Furthermore, soldering often results in fine and very fine dust, which can be deposited in the alveoli after inhalation and thus can pass directly into the bloodstream.

Direct contact with solder fumes and soldering vapour represents an increased health hazard for the eyes, skin, lungs and respiratory tract.

Professional extraction is therefore essential for soldering without causing harm to the environment or your health.

Electrostatic air filters are particularly suitable for the separation of very small particles (separation up to 0.01μm) and provide a separation efficiency of up to 99%. The operating principle is described on the underside of the electrostatic air filter - description of operation.

It is best to use our elstar filters when filtering soldering fumes or soldering vapours.

Welding smoke separator, welding smoke filter

Laser smoke occurs in laser metalworking such as laser cutting, laser stamping, laser welding or laser engraving. The main components of laser and welding fumes are CO/CO2, ozone and arc vaporized metal. Extremely small and very fine particles are released into the ambient air, which may pose different health hazards depending on the quantity and the metal material.

Contact with welding smoke or laser smoke should be avoided and vapour extraction in the workplace is mandatory. Electrostatic filters and electrostatic separators can filter out up to 99% of the particles.

Electrostatic air filters are particularly suitable for the separation of very small particles (separation up to 0.01μm) and provide a separation efficiency of up to 99%.

The associated dust filters of the duster series are the right choice for air purification.

Inorganic dusts can result in serious lung diseases. The disease depends on the mobility of the dust particles.

Dust inhalation diseases are often occupational and are directly related to daily work or work processes. The effects of pulmonary fibrosis are often only detected many years later. It is therefore important to collect and filter the dust at the point of origin or the point of exit.

It is therefore essential to comply with the legal provisions and have the associated air purification for employee protection. Our filters can be optimally adapted to your polluted air in order to achieve the most purified air possible. Various pre- and post-filters allow for a flexible upgrading of the filter. Automatic cleaning mechanisms and well thought-out collection containers allow for nearly contactless disposal of the dust.

The devices of the dustar series are the right choice here.