Forcing molten metals into mold cavities at high pressure in Die Casting processes can result in large amounts of oil mist and oil smoke that contain dry, sticky particles of release agent and piston cooling oil. Release agents used for lubricating molds can contain wax and silicon - a higher wax and silicon percentage makes the emission more sticky and more challenging to filter.

Die casting extraction installation from Absolent AB and Hungarian distributor Pure Air with hood designed by Ales Kolsek from Kemol

Exposure to oil mist and oil smoke can result in a number of issues including respiratory diseases and lower productivity, as well as incurring additional cleaning and energy costs. This means that it is vital to design an LEV system that is capable of capturing the contaminated air before it has a chance to escape into the atmosphere. Once captured, the air then needs to be filtered to remove the harmful particulate. The sticky nature and volumes of particles generated in Die Casting means some filters, particularly first stage filters, can quickly ‘blind’ - however, Absolent’s A.Smoke range is specifically designed for heavy oil smoke applications like Die Casting.

Absolent filters offer three stages of filtration – a pre-filter to capture larger ‘sticky’ particles, a secondary filter for particles 0.1 – 10 microns in size, and then a final HEPA filter for sub-micron particles. The materials used in each filter cassette can be developed to suit specific customer requirements based on Absolent’s extensive industry experience. A spray system can also be included to assist the self-cleaning function of the filter cassettes.

Paul Battersby, UK Sales Manager (Oil Mist), comments, “According to the Cast Metals Federation there are over 400 foundries in the UK producing precision engineered components worth around £2.2B annually. This includes over 70 companies that provide die casting services.

“Like all employers, foundries are legally required to protect their employees from exposure to hazardous airborne contaminants under COSHH (Control of Substances Hazardous to Health) Regulations 2002. Effectively controlling airborne particulate generated in Die Casting can be notoriously tricky, but Absolent has developed a range of products designed specifically for this purpose. This includes a Die Cast hood which can be adjusted to fit Die Cast machines of all sizes and is ideally suited to work in tandem with Absolent’s A.Smoke range.

“A dedicated questionnaire for Die Casting companies means we can capture all of the information required at the outset to ensure the customer receives the best possible Absolent solution for their specific requirement. Customers are asked a number of questions including what brand of release agent they are using, the specification of the release agent, % of wax concentration, amount used per cycle etc. Similar questions are also asked about piston lubrication.

“The suggested system takes all of this information into account to decide what airflow is required for each specific Die casting machine and the recommended solution is determined by a calculation which accounts for how each individual machine is operated. This way customers can be confident they are investing in the best solution for their premises, and not just an off-the-shelf, one size fits all product.”

As well as specifying and installing effective local exhaust ventilation (LEV), Filtermist also offers a comprehensive aftermarket service that includes service, maintenance, spares, consumables, LEV Testing and Air Monitoring.

Contact Filtermist’s team by calling 01952 290500 or emailing sales@filtermist.com to find out more.