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AMBIENT AIR CLEANERS: WHEN & WHERE TO USE THEM

In industrial environments, particularly those involving welding, plasma cutting, and manufacturing processes, air quality is not just a comfort issue—it's a critical health and operational concern. While many facilities focus on source capture solutions as their primary approach, ambient air cleaners represent an essential secondary system in a comprehensive air quality management strategy.

The Dual-Action "push, pull" Approach

In welding environments, ambient air purification systems function as a complementary method that captures contaminants missed by the primary filtration equipment. This creates a comprehensive air quality management approach:

• Primary systems (source capture) "pull" contaminants directly at the source
• Ambient air cleaners "push" filtered air back into the space while continuously removing remaining particulates

These versatile systems continuously filter and recirculate air throughout your facility, reducing the overall concentration of airborne contaminants. When properly implemented, ambient air cleaners can reduce airborne particulate by 80-85%, creating a healthier, more productive workplace while potentially saving thousands of dollars annually in heating and cooling costs compared to traditional exhaust methods.

This guide will help you understand when and where ambient air cleaners should be deployed, how to select the right unit for your specific needs, and how to maximize their effectiveness as part of your overall air quality strategy.

UNDERSTANDING AMBIENT AIR CLEANERS

What Are Ambient Air Cleaners?

Ambient air cleaners work as secondary systems that extract contaminants not removed by primary collection solutions. Unlike source capture systems that target contaminants at their origin, ambient air cleaners continuously process the general air in a facility, gradually reducing the concentration of particles throughout the entire space.

How Do They Work?

These systems draw in contaminated air, pass it through a series of filters designed to capture particles of various sizes, and then recirculate the cleaned air back into the workspace. The innovative T-pattern airflow design featured in units like the OX series creates optimal circulation patterns that maximize cleaning efficiency.

Most industrial-grade ambient air cleaners utilize multi-stage filtration:

1. Pre-filters (typically pleated filters with 35% efficiency) capture larger particles
2. Main filters (often bag filters with 95% efficiency or MERV 15 rating) trap smaller particulates
3. After-filters (which may include carbon filters or HEPA filtration) address specific contaminants like odors or ultra-fine particles

WHEN TO USE AMBIENT AIR CLEANERS

1. As a Complement to Source Capture Systems

The most effective air quality management strategy uses ambient air cleaners in conjunction with source capture systems. While source capture should always be your primary approach for controlling weld fumes and other contaminants, ambient air cleaners address the inevitable fugitive emissions that escape primary collection.

2. For General Air Quality Improvement

Even in facilities where source capture effectively manages most contaminants, ambient air cleaners provide valuable secondary filtration that addresses:

• Background dust and particulate
• Residual contaminants from adjacent processes
• Outdoor pollutants entering through doors, windows, or ventilation
• General improvement of indoor air quality for all workers 

3. When Source Capture Is Not Feasible

In some operations, source capture presents significant challenges:

• Large structural fabrication where parts cannot be easily positioned near extraction points
• Mobile welding operations throughout a facility
• Historic facilities where ductwork installation is impractical
• Temporary or changing work configurations

In these scenarios, strategically placed ambient air cleaners may represent the most practical solution for maintaining acceptable air quality.

4. For Specialized Contaminant Control

Certain manufacturing processes generate specific contaminants that benefit from dedicated ambient filtration:

Chemical Odors and VOCs: Models with carbon filtration (like the FX-AC-2500D-CCP with 112 lbs of carbon) effectively capture and neutralize odors and volatile organic compounds
Ultra-Fine Particulates: HEPA filtration options (such as the FX-AC-2500D-HE) can capture 99.97% of particles as small as 0.3 microns
Mixed Contaminants: Combination units like the FX-AC-2500D-CCPHE address both particulates and odors simultaneously

AIR CLEANER PLACEMENT

Strategic placement is crucial for maximizing the effectiveness of ambient air cleaners. Consider these key deployment locations:

Central Facility Areas

Ambient air cleaners positioned in central, open areas of your facility can efficiently process the largest volume of air. This placement works well for:

• Large manufacturing floors with multiple process areas
• Central aisles or corridors where air naturally circulates
• Areas with high ceilings where contaminants tend to accumulate

Problem Zones with Known Air Quality Issues

Some areas consistently experience higher contaminant levels due to:

• Process concentration (multiple welding stations in close proximity)
• Limited air circulation (corners, alcoves, or areas with physical barriers)
• Proximity to doors or other sources of external contaminants
• Limited access for source capture equipment

These areas benefit from dedicated ambient air cleaners sized appropriately for the space and contaminant load.

Near Sensitive Equipment or Materials

Certain production areas contain equipment or materials sensitive to airborne contaminants:

• CNC machinery with precision components
• Electronic assembly areas
• Quality control stations
• Finished product storage

Placing ambient air cleaners near these areas provides an additional layer of protection against particle contamination.

Break Rooms and Office Areas Adjacent to Production

Staff facilities located near production areas often experience air quality issues that can be effectively addressed with appropriately sized ambient air cleaners. This creates healthier spaces for employees during breaks and administrative work.

In a Calculated Grid Pattern for Large Facilities

For extensive manufacturing spaces, ambient air cleaners should be arranged in a calculated grid pattern based on:

• The volume of the space (height × width × length)
• The number of air changes per hour required
• The types and concentrations of contaminants
• Air flow patterns within the facility

Choosing the right air cleaner

Calculating Required Capacity

Determining the appropriate capacity for your ambient air cleaner is essential for effective performance. A common rule of thumb is to provide 6-12 air changes per hour for industrial environments with moderate contaminant levels.

Basic Calculation:

1. Calculate your room volume in cubic feet (length × width × height)
2. Multiply by the desired number of air changes per hour (6-12 for most applications)
3. Divide by 60 to get the required CFM (Cubic Feet per Minute)

Example: For a 30' × 50' room with 20' ceilings:

Volume = 30 × 50 × 20 = 30,000 cubic feet
For 8 air changes per hour: 30,000 × 8 = 240,000 cubic feet per hour
Required CFM = 240,000 ÷ 60 = 4,000 CFM

This calculation indicates that an OX4000 unit or multiple smaller units with a combined capacity of 4,000 CFM would be appropriate.

Matching Filtration to Your Contaminants

Different manufacturing processes generate different types of contaminants. Select filtration options based on your specific needs:

For Welding Fumes and General Manufacturing Dust:

For Processes Generating Odors or VOCs:

For Ultra-Fine Particulates or More Demanding Applications:

Max Effectiveness Through Proper Implementation

Strategic Placement for Optimal Air Flow

To achieve the most effective air circulation:

• Position units to create circular airflow patterns throughout the space
• Avoid placing intake near exhaust to prevent short-cycling of air
• Consider natural thermal currents (hot air rises, cool air falls)
• Ensure intakes are positioned where contaminants naturally accumulate

Monitoring and Maintenance

Regular monitoring and maintenance are essential for optimal performance:

Filter Monitoring:

• Install Magnehelic gauges to measure pressure drop across filters
• Establish baseline readings when filters are new
• Schedule replacements based on pressure differential changes

Typical Filter Replacement Schedule:

• Pre-filters: Every 2-3 months
• Bag filters: Every 4-6 months
• After-filters (HEPA filters, Carbon filters): Every 6-12 months

These intervals may vary based on your specific application and contaminant load.

COMPARING Ambient AIR CLEANER MODELS

OX Series for Heavy-Duty Industrial Applications

The OX series offers robust solutions for demanding industrial environments:

FX Series for Specialized Applications

The FX series provides targeted solutions for specific air quality challenges:

Ambient air cleaners represent a critical component of a comprehensive air quality management strategy for industrial facilities. When properly selected, positioned, and maintained, these systems offer significant benefits:

By understanding when and where to deploy ambient air cleaners—and selecting the appropriate model for your specific needs—you can create a healthier, more efficient workplace while realizing substantial long-term cost savings.

For assistance in developing a customized ambient air cleaner solution for your facility, contact our specialists. Our team can provide expert guidance on system selection, placement strategy, and integration with your existing air quality management approach.

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• Welding Fume Exposure and Long-Term Health Issues

• Fume Extraction in Welding: Ensuring Safety and Air Quality