Challenge
A major manufacturing facility contacted Effective Controls, a distributor of Airex Industries solutions based in Pennsylvania, to address a significant challenge in capturing air contaminants directly at the source. Their dual torch-cutting tables, which spanned up to 60 feet, generated extensive smoke during operation. The existing overhead curtain hoods, while helpful, were insufficient in controlling the smoke and fumes over such a large surface area. This left the facility with significant air quality issues, making it impossible to fully ventilate the space using traditional methods.
Solution
To address this, an innovative zipper duct design was developed. This solution focused on optimizing airflow directly above the cutting zone, dramatically reducing the amount of air required for effective ventilation. The zipper duct system dynamically follows the torch’s movements, ensuring targeted air capture and minimizing wasted air volume.
By implementing this system, the facility was able to contain smoke emissions with only 15% of the air required for a full-table ventilation solution. This not only improved air quality but also significantly reduced energy consumption.
Specifications
• Units: DCCH-20 & HEPA
• Air Volume: 10,000 CFM
• Media: Paper & HEPA
• Air-to-Cloth Ratio: 1.5:1
Conclusion
The custom zipper duct solution effectively managed smoke emissions, enhanced air quality, and optimized energy use, providing the facility with a scalable, efficient, and environmentally responsible ventilation system.
