Filtration Solutions for Stamping Operations

Filter longevity is a constant challenge in stamping operations. Fine metal dust, sticky hydrocarbons, and oily residues from metalworking fluids and antispatter fluids can quickly clog filters, reducing airflow and driving up maintenance costs. Extending filter life requires the right filter media, strategic system design, and consistent maintenance. Here’s how you can address common filtration challenges such as antispatter, hydrocarbons and combustible dusts.

Dust Collection for Stamping

Stamping is a cornerstone of modern manufacturing, transforming metal sheets into precisely shaped parts for industries like automotive, aerospace, military and defense, and electronics. This high-pressure process uses powerful machinery to cut, shape or emboss metal with speed and accuracy. However, the process doesn’t just produce precision parts—it also generates a complex mix of fine metal dust, fumes and oily residues from lubricants, metalworking fluids and antispatter sprays.

The byproducts of stamping present serious health and safety concerns, including:

• Respiratory Hazards:Fine metal particulates and fumes can linger in the air, increasing the risk of lung diseases with prolonged exposure.
  
• Skin Irritation:Oily mists and residues from hydrocarbon-based products can cause irritation and discomfort for workers.
• Poor Air Quality:Accumulated contaminants degrade indoor air quality, impacting worker health and comfort.
• Combustion Risks:The combination of metal dust and hydrocarbons creates a highly combustible environment, increasing the likelihood of fires or explosions if not properly managed.

Addressing Filtration Challenges in Stamping

Dust collection systems are essential in stamping operations, but they face unique challenges. The fine, often sticky nature of the particles produced makes filtration difficult, leading to clogged filters and reduced system efficiency. Hydrocarbons and oily residues can coat filter media, shortening filter life and requiring frequent maintenance or replacement. The variability of the particulates—ranging from fine mists to larger metallic particles—further complicates the design of an effective dust collection system. Managing these challenges requires specialized filtration solutions that can handle sticky residues, prevent filter blinding, and maintain compliance with strict air quality and safety standards. These are a few of the challenges in air filtration faced by stamping operations.

Antispatter

In stamping operations, antispatter plays a critical role in protecting parts and tooling from molten drops of metal created by welding and other metalworking operations. Typically applied as a spray or liquid, antispatter forms a protective barrier on tooling, workpieces or equipment, making it easier to remove spatter and maintain clean, functional surfaces.

Challenges: While antispatter protects equipment and improves operational efficiency, it presents unique challenges for dust collection systems. The high water content in many antispatter formulas can saturate cartridge filter media. When filters absorb moisture, their fibers expand, blocking airflow and reducing the system’s efficiency. Cellulose filter media, in particular, is prone to breaking apart during filter pulsing when it becomes saturated, leading to frequent replacements and downtime.

What to do: To extend filter life and ensure efficient dust collection when using antispatter, consider the following best practices:

• Upgrade Filter Media:Use spunbond polyester filters with an oleophobic (oil-repellent) coating.
• Contain Spray Residues:Employ containment devices to minimize overspray and ensure the torch is completely enclosed during application, reducing airborne residues.
• Adopt the Bowl Method: Dip the torch into a bowl of antispatter liquid instead of spraying, which minimizes aerosolization and airborne contaminants.
• Install Pre-Filtration Systems:Use a mesh and baffle system or roughing filters to capture aerosols and larger droplets before they reach the main cartridge filters.
• Apply Pre-coat Materials:Consider a continuous application of pre-coat materials, such as expanded perlite, to form a protective barrier on filter media. Precoats help absorb excess moisture and prevent filter clogging.

Hydrocarbons

Hydrocarbons are common byproducts of stamping and metalworking operations. Lubricants are commonly used in stamping to help stamped parts release from molds and dyes. Stamping operations may also use metalworking fluids (MWFs) for cutting, grinding and other production processes. Lubricants and MWFs used in stamping are usually petroleum-based but are sometimes made of vegetable oils or animal fats (fatty acids). When these materials are vaporized during high-heat processes such as welding or laser cutting, they create a sticky airborne hydrocarbon residue that settles on surfaces.

Challenges: Hydrocarbons can wreak havoc on dust collection systems. The sticky, oily nature of these compounds can coat filter media, reducing airflow. In a short amount of time, this buildup leads to clogged filters that are harder to clean, even with filter pulsing systems.

What to do: To mitigate the impact of hydrocarbons and maintain efficient dust collection, consider these strategies.

• Reduce lubricant use or clean parts: Minimize the amount of lubricant applied during stamping to reduce airborne hydrocarbon residues. You can also implement cleaning processes, such as part washing or wiping, to remove residual oils and lubricants from parts before they enter other production stages, such as welding.
• Consider changing lubricants: Switch to low-viscosity or water-soluble lubricants that produce fewer airborne hydrocarbons and are easier to filter. Lubricants with more than 15% active product will cause more hydrocarbon buildup.
• Use Oil-Resistant Filters: Install filters with oleophobic (oil-repellent) coatings to prevent hydrocarbon buildup on the media.
• Pre-Filtration Solutions: Add a mesh and baffle system or roughing filters to capture large droplets and reduce the hydrocarbon load on the main cartridge filters.
• Apply Pre-Coat Materials: Use pre-coat materials like expanded perlite to create a barrier on the filter media. This prevents sticky residues from clogging filters and absorbs excess hydrocarbons.

Filter Care for Stamping Operations

Stamping operations have unique challenges when it comes to filter longevity and effectiveness, but there are practical steps you can take to reduce problems caused by hydrocarbons and antispatter. Strategies such as containment devices, pre-coat and pre-filtration can significantly reduce the impact of lubricants and antispatter fluids on dust collector filters. Choosing high-quality polyester or blended filters with an oleophobic treatment will also go a long way toward extending filter life.

Proper filter care and maintenance are also essential. These steps will help you get more life out of your filters.

• The dust collection system should have a pulse-cleaning system to remove excess dust from the filter surface, which helps to prevent dust buildup, maintain airflow, and extend filter life in demanding applications like stamping.
• Regularly inspect and change filters to prevent buildup and ensure efficient airflow. Monitor the pressure drop across the filters to determine when they are loaded.
• In addition, routinely check ductwork, seals and other system components to minimize contaminants reaching the filters.

Struggling with clogged, dirty filters in your stamping operations? Talk to the filtration experts at RoboVent! We can help you select the right filters for your operations and implement filter-saving strategies such as antispatter containment and continuous pre-coating.