A global medical device manufacturer upgraded to MistBuster mist collectors to manage increased oil mist from high-speed cobalt machining. Custom mounts and plenums enabled a compact install, improving air quality and machine performance in under six weeks.
Challenge
This manufacturer machines medical-grade parts where extremely tight tolerances and high spindle speeds (e.g., 17,000 RPM) demand aggressive use of lubricants and coolants to maintain tool life and part accuracy.
The shift to cobalt (from titanium) for a new product line introduced more heat and mist into the process, raising concerns around air quality, machine reliability, and potential safety hazards.
The client’s existing CNC machines needed upgraded mist collection to handle:
- High-pressure coolant systems
- Increased oil mist volume
- Strict floor-to-ceiling height limitations (“cubby” install area)
AFS Solution
Air Filtration Systems designed a custom mounting and plenum setup to ensure each unit fit within the constrained vertical space above the CNC enclosures.
We provided a combination of:
- MistBuster 850 and MistBuster 2000 units
- Incorporated fire damper actuator into duct
- Locally fabricated plenums tailored to fit tight clearance and optimize airflow
- Seamless integration with the existing CNC machines without disrupting production
The Results
- Full system designed, staged, and installed in under 6 weeks
- Enabled continued use of advanced coolants without mist buildup
- Improved air quality, equipment reliability, and operator safety
- Scalable mist control solution for future production lines
