Oil mist is released into the air when metalworking fluids are used to cool or lubricate machine tools and parts during the manufacturing process. Airborne oil mist is harmful to human health and poses a serious threat to the environment. This is why employers need to use a mist collector system to minimize the negative effects of working with metalworking equipment.

A proper collection system helps to improve worker safety and efficiency, reduce liability risks for workers, protect capital plant and machinery, and meet workplace exposure regulations. Airborne oil mist particles can cause eye and skin irritation, shortness of breath, vomiting, headaches, fatigue and other health problems. To avoid these health hazards, employees need to wear specialized protective chemical-protective clothing, aprons and encapsulated suits. However, this only mitigates the risk to a degree. Employers need to implement a system that is able to remove oil mist from the air before it can harm workers and the environment.

Using an industrial mist collector helps to prevent this damage to the environment and the human body by separating the oil from the water and air. This is accomplished through a series of stages: the mist is drawn into the filter, where it coalesces and forms droplets. These are then drained from the filter via gravity. The remaining swarf and water is then filtered out by the washable pre-filter and returned back into the factory for reuse.

An oil mist collection system is usually composed of a ductwork and a washable filter. The ductwork takes in the air contaminated with the oil mist, which is then passed through the washable pre-filter to separate most of the liquid. This is then drained away into a waste container. The clean air is then passed through a HEPA or DOP final stage to purify it.

The best type of oil mist collector is a baffle plate-type. This type of system has a simple structure and is easily manufactured at low cost. Experiments and numerical simulations have shown that the maximum oil mist collection rate can be achieved with six plates. The arrangement of the plates on the downstream side affects the pressure loss, but does not significantly influence the collection efficiency. The collection efficiency C/DP is equal to the collection rate divided by the dimensionless pressure drop DP. The system can be fitted with a high-efficiency afterfilter to achieve a more complete separation of oil and water from the swarf. This makes it possible to recycle up to 90% of the oil and processing fluid. This can be a great benefit in the workshop and help to save money on new metalworking fluids. A good mist collection system is able to capture oil and water from the swarf and return it back into the factory for reuse. This can increase the production of machines by reducing downtime and the need for new metalworking fluids. It can also increase the productivity and efficiency of workers. This system is also highly energy efficient, and is a great option for industrial applications.

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