Low-emission welding production through integrated air technology
CASE STUDY: WELDING FUME EXTRACTION FOR ROBOTIC AND MANUAL WELDING WORKSTATIONS AT A A leading agricultural machinery manufacturer has been able to significantly reduce emissions in its welding production whilst simultaneously lowering the energy consumption of the filtration system, thanks to a new ventilation solution. This solution captures ultrafine particles up to 45 per cent more effectively, whilst energy consumption can be reduced by up to 35 per cent.
The challenge
In a newly constructed prefabrication center, large amounts of welding smoke and fine dust are generated at robot and manual welding workstations. A comprehensive air technology solution was sought that reliably captures all emissions while meeting high requirements for energy efficiency and occupational safety.
Particular challenges arose from the combination of different extraction systems, a fresh air supply with up to 100% outside air, and the high demands of continuous 24/7 operation. Furthermore, the system should be flexibly expandable and operate reliably even under partial load.
The solution
With Kappa A.I.R.™, a holistic air technology solution was implemented that captures, cleans, and energetically utilizes process and room air in an integrated system.
Welding emissions are captured directly at the robot and manual welding workstations as well as in the hall area and are highly effectively cleaned of fine dust.
An integrated heat recovery system utilizes the existing process heat for the efficient preheating of fresh air and sustainably reduces the energy demand of the system.
Through intelligent air volume control, the system performance is automatically adjusted to the actual production needs. The modular design and partially redundant configuration ensure high availability even during maintenance work or in partial load operation. At the same time, the system remains flexible for future expansions.
The results
The new air technology has created optimal conditions for low-emission and energy-efficient welding production.
Key results at a glance:
- reliable capture of welding smoke, fine dust, and diffuse emissions
- up to 35% energy savings through demand-based air volume control
- highly efficient heat recovery with up to 100% fresh air operation
- partially redundant system structure for high operational reliability
- modular expandable to up to 12 filter modules
- designed for continuous 24/7 operation
Project conclusion
The new air technology solution combines effective emission reduction with high energy efficiency and operational reliability. Thanks to intelligent control, integrated heat recovery, and a modular system structure, a future-proof solution has been created that permanently meets the demands of modern welding production.