Emulsion Mist Separators: Work Safely, Cleanly, and Emissions-Free!
We offer customized extraction solutions for emissions generated during metalworking processes such as drilling, turning, milling, grinding, and many others.
Where are emulsion mist separators used?
In metalworking, drilling, turning, milling, and grinding produce oil mist, smoke, and emulsion mist. The use of cooling lubricants causes hazardous aerosols to be released into the environment during the machining process. This oil or emulsion mist degrades indoor air quality and contaminates production areas by coating workbenches, machines, walls, and floors with a fine layer of oil. This increases the risk of slipping and falling and reduces process stability. In addition, emulsion mist can cause serious skin and respiratory diseases.
What does an emulsion mist separator do?
An emulsion mist collector is a specialized device that can be used in industrial environments to remove harmful aerosols from the air. We offer high-quality equipment and extraction systems that extract and purify most of the harmful emulsion mist from machine tools. Our systems are particularly well-suited for extracting oil mist, emulsion mist, and smoke. They remove coolant mist from the contaminated air generated by machining centers, ensuring a clean and safe working environment.
An emulsion mist separator offers you the following benefits
Our emulsion mist collectors are particularly well-suited for metalworking facilities that place a high priority on air quality, employee health, environmental protection, energy efficiency, and operational safety. The key benefits of emulsion mist collectors are:
Improved Air Quality
By effectively removing emulsion mist, oil mist, and smoke, emulsion mist separators ensure clean and healthy air in production environments. They provide efficient capture and reliable purification of the exhaust air from a machine tool. With our HEPA H13 post-filters, the captured air is purified to over 99.95%.
Short delivery times and easy self-assembly
Our emulsion mist collectors offer the advantage of quick setup, which – thanks to their user-friendly design and clear instructions – can be easily done by you. In addition, we guarantee short delivery times, so you’ll receive the unit promptly and can put it into operation without delay. This ensures that your production continues to run smoothly.
Improved Workplace Safety
Emulsion mist collectors prevent hazardous aerosols from settling on surfaces and forming a slippery film. This significantly reduces the risk of falls and workplace accidents, resulting in a safer work environment.
Longer service life of the machines
Removing harmful aerosols from the air protects machines and tools from deposits and contamination. This results in a longer service life for the machines, reduced maintenance needs, and less downtime.
Cost savings
Less contamination means less effort and lower costs for cleaning the work environment. In addition, modern separators are energy-efficient, which reduces energy consumption and operating costs.
Compliance with Legal Requirements
Many industrialized countries have strict regulations regarding air quality and workplace safety. The use of emulsion mist collectors helps companies comply with these regulations, providing legal protection and helping them avoid penalties.
Improved employee satisfaction and retention
A clean and safe work environment contributes to employee satisfaction and can increase employee retention during times of labor shortages. Healthy working conditions reduce sick days and boost the workforce’s motivation and productivity.
THE LONG-LIFE SEPARATOR
The Longlife separator is the core component of our mechanical AFS air purification units. It is self-cleaning, completely maintenance-free, and offers extremely high separation efficiency. Thanks to a sophisticated airflow design, all particles larger than 2.0 µm are almost completely removed from the airflow. Independent studies confirm the high separation efficiency of the AFS Longlife separator:
Special Features of AFS Emulsion Mist Separators
AFS’s emulsion mist separators offer outstanding solutions for air purification in metalworking facilities. That’s why our emulsion mist separators are the perfect solution for you. Our unique selling point is our Longlife baffle plate separator in the pre-separation stage. It removes almost all particles larger than 2 µm from the air. And best of all, the Longlife baffle plate separator does this maintenance-free. This saves you money on replacement and wear-and-tear parts.
High separation efficiency
Our emulsion mist collectors are characterized by their high efficiency in removing emulsion and oil mist from the air. They reliably remove cutting fluid mist from the contaminated air emitted by machining tools, thereby ensuring a clean and safe working environment. With a HEPA H13 post-filter, the filtration and separation efficiency exceeds 99.95%. To prevent the H13 filter from clogging too quickly and requiring replacement, we use our Longlife baffle plate separator—specially developed for the separation of emulsion mist—in the pre-separation stage.
Comprehensive Service, Environment, and Sustainability
AFS not only offers delivery and installation of air purification equipment, but also comprehensive services, replacement parts, and wear parts. This maximizes the service life of the systems and increases operational reliability. Most of our separators are cleanable and washable. Filters and separators can be cleaned in our in-house parts washing facilities. Afterward, they are almost like new again. Clean instead of throwing away.
Integration with Ventilation Systems
We can seamlessly integrate our emulsion mist collectors into existing ventilation systems, including heat recovery systems. This ensures comprehensive air purification and temperature control in production areas.
Fast delivery times for replacement parts and emulsion separators
Our emulsion mist collectors, replacement parts, and accessories for emulsion mist collectors are available within a few weeks. This means you won’t have to deal with long delivery times and can quickly enjoy the benefits of our high-quality air purification systems. We ensure that you can improve your production environment quickly and efficiently.
Best Energy Efficiency
Our emulsion mist separators are known for their superior energy efficiency. They help you reduce operating costs while protecting the environment. Thanks to their low energy consumption, our systems contribute to sustainable and cost-effective production.
Low maintenance requirements
A key advantage of our emulsion mist separators is their efficient pre-separation, which significantly extends the service life of the afterfilters. As a result, you benefit from low maintenance requirements. Our Longlife baffle plate separator is virtually wear-free and, when handled with care and properly, will last for the entire service life of the machine.
Product Variants and Data Sheets
We offer a variety of products to meet your needs, which differ primarily in terms of suction power. Click on a product to learn more about each one. You’re also welcome to contact us directly to find out which product is best for you.
AFS 400 C
AFS 600
AFS 06M
AFS 1100
AFS 1600
AFS 3000
AFS 4000
AFS 6000
AFS 8000
AFS 12000
AFS 16000
AFS 10M
AFS 11M
New product series for the AFS 1100 / 1600
- Achieve up to 20% energy savings compared to the previous version
- Offer higher separation efficiency
- Quieter
- Feature improved airflow management
- Easier to maintain
Are you interested in our emulsion mist separators?
Please feel free to contact us. We’d be happy to advise you and send you a no-obligation quote.
FAQ: More Information on Emulsion Mist Separators
An emulsion mist separator removes emulsion mist and other aerosols from the air generated during industrial processes. The air purification process consists of 6 steps:
First, the contaminated air containing emulsion mist or oil mist is extracted from the machine tool or the emission source and drawn into the emulsion mist separator by negative pressure. This air can be extracted directly from production machines.
Second, during the pre-separation stage, larger particles are mechanically removed, e.g., by centrifugal force in our impact plate separator or by gravity in the filter media. This reduces the load on the subsequent filtration stages and increases efficiency and sustainability.
This is followed by the post-separation or post-filtration stage. Depending on what is to be done with the purified air, metal mesh separators or filters—such as HEPA H13 filters—can be used. If the air is discharged outdoors, metal mesh post-separators are sufficient. The advantage: These are cleanable and washable, and thus virtually wear-free. Disadvantage: Fine aerosols and particles are not retained; however, this is feasible and permissible for discharge to the outdoors in accordance with applicable emission control guidelines.
If the purified air is to be returned to the hall as recirculated air and circulate there, a HEPA H13 post-filter is absolutely necessary. The emulsion and emulsion mist contain, for example, many chemicals, bacteria, fungi, etc. You do not want these to be finely atomized in the indoor air and inhaled. A HEPA H13 filter removes over 99.95% of all particles and aerosols larger than 0.3 µm.
Advantage: High-efficiency and reliable purification of the machine exhaust air.
Disadvantage: H13 filters are consumable parts and must be replaced when they become clogged.
Mechanical filters consist of special fabrics or fiber materials that trap fine particles. Due to their inertia, these particles strike the filter fibers and remain stuck there.
Coalescence filters combine small droplets into larger ones, which can then be more easily separated and drained by gravity. However, this requires a slow airflow and a large filter area, necessitating larger filters and equipment.
Centrifugal separators cause the airflow to rotate. Centrifugal force flings the droplets or particles out of the air, where they are separated. A disadvantage of this method is that it reaches its limits when dealing with very fine droplets and particles.
Longlife baffle plate separators, available exclusively from AFS, also use centrifugal force to separate particles and aerosols. Unlike centrifugal separators, however, the air is not set in rotation here. Instead, the air is deflected multiple times by specially designed baffle plates. This results in higher flow velocities and exceptionally high separation efficiency. Furthermore, this system operates with virtually no maintenance and minimal wear.