Welding Station Fume Purification Solution: Application Record of KNOKOO FES600 Fume Extractor

Welding fumes are an "invisible health killer" and an "environmental stumbling block" in machining workshops. Especially in industries with extremely high requirements for the production environment, such as precision hardware and medical devices, the tiny particles and harmful gases generated during welding not only affect product processing precision but also directly violate environmental red lines and employee health limits. A precision hardware processing plant in Guangdong once faced production difficulties due to welding fume problems. The successful application of the KNOKOO FES600 fume extractor provided them with a complete solution of "source capture + high-efficiency purification." This article will analyze how this device solves the welding fume problem from a practical application scenario.

I. Project Pain Points: The Fume Problem Exacerbates the Precision Machining Situation

This precision hardware processing plant primarily provides high-precision hardware parts for the new energy vehicle and medical device industries. The workshop has 12 welding stations, mainly using argon arc welding and laser welding. Compared to traditional welding, this type of precision welding produces finer fume particles (mostly 0.1-1μm in diameter) and higher concentrations of harmful substances, making traditional treatment methods ineffective. The specific pain points are concentrated in three areas:

- Fume diffusion affects product quality: Fine welding fume particles adhere to the surface of hardware parts being processed or already processed, causing scratches and stains. This increases subsequent cleaning costs by 30%, and 15% of products are scrapped due to substandard precision caused by fume pollution, resulting in direct economic losses.

- Dual pressure on employee health and compliance: The workshop is highly enclosed, making it difficult for fume to diffuse naturally. Actual measurements showed that the fume concentration around the workstations reached 15mg/m³, far exceeding the 1mg/m³ standard stipulated in the "Occupational Exposure Limits for Hazardous Factors in the Workplace". Several long-term employees experienced respiratory allergy symptoms, the rate of abnormal occupational health check-up reports increased, and regular inspections by environmental protection departments also posed a significant risk of hefty fines to the company.

- Traditional equipment suffers from "difficult capture and poor purification": The company had tried using mobile exhaust fans and simple purification devices, but the exhaust fans had limited smoke extraction range, with a smoke capture rate of less than 50%; the simple purification devices could only filter large particles and were almost ineffective against fine smoke and harmful gases, and a pungent odor could still be detected after operation, meaning the problem remained unresolved.

After comparing more than 10 similar devices and conducting two weeks of on-site testing, the company ultimately decided on the KNOKOO FES600 smoke extractor as its core solution.

II. Core Solution: How Does the FES600 Solve the Problem of Precision Welding Fume?

The KNOKOO FES600 fume extractor is not simply a "suction + filtration" device, but a "high-efficiency capture + deep purification" system tailored for precision welding scenarios. Its core advantages precisely match the company's needs, making it the preferred solution:

1. 360° Precise Capture, Blocking Fume Diffusion at the Source

The root cause of fume diffusion lies in "untimely capture." The FES600 is equipped with a customized universal fume extraction arm made of highly elastic, wear-resistant flexible tubing, allowing for 360° angle adjustment. The extraction port can precisely target the welding point (minimum distance as low as 5cm). Simultaneously, the built-in high-pressure centrifugal fan generates strong negative pressure, with a fume extraction velocity of 18m/s. Welding fumes are instantly sucked in as soon as they are generated, achieving a capture rate of up to 99%, completely solving the problem of traditional equipment "not being able to completely extract" fumes. For the company's laser welding station, KNOKOO has also specially equipped it with a heat-resistant fume extraction hood to prevent high-temperature welding slag from damaging the equipment, making it more adaptable.

2. Four-Stage Deep Purification for "Standardized Emissions + Air Circulation"

The difficulty in absorbing fumes from precision welding lies in the fine particles and complex composition. The FES600 employs a four-stage purification process: pre-filtration + HEPA high-efficiency filtration + activated carbon adsorption + photocatalytic oxidation. This process progressively breaks down pollutants: the first-stage pre-filtration layer intercepts welding slag and large dust particles, extending the lifespan of the core filter material; the second-stage HEPA H13 filter material achieves a 99.97% filtration efficiency for 0.1μm particles, thoroughly filtering fine fumes; the third-stage columnar activated carbon adsorption layer efficiently adsorbs harmful VOCs such as benzene and formaldehyde, removing pungent odors; and the fourth-stage photocatalytic oxidation module decomposes residual organic pollutants into harmless water and carbon dioxide. Third-party testing shows that the particulate matter concentration in the purified exhaust gas is only 0.12 mg/m³, and the VOCs concentration is below 10 mg/m³, reducing energy consumption for fresh air intake in the workshop.

3. Intelligent and Convenient Design, Adapted to the Production Pace of Precision Workshops

Precision machining workshops have extremely high requirements for equipment stability and convenience. The FES600's intelligent design perfectly meets these needs: the equipment is equipped with an intelligent control panel that allows for one-button start/stop and can adjust the airflow according to welding conditions. It can be set to high speed for laser welding to enhance suction and low speed for argon arc welding to save energy. A built-in filter clogging warning system automatically alarms when the filter reaches saturation, reminding staff to replace it and preventing filter failure from affecting purification efficiency. The equipment operates at a noise level below 70dB, ensuring it won't interfere with precision operations or employee communication within the workshop.

4. Low-Cost Operation and Maintenance, Worry-Free Long-Term Use

For businesses, the long-term operation and maintenance costs of equipment are crucial. The FES600 uses an energy-saving motor with a power consumption of only 0.8kW. With 12 units operating simultaneously for 8 hours, the daily electricity cost is only 76.8 yuan (calculated at 1 yuan/kWh for industrial electricity). The filter media features a modular design, making replacement simple and convenient. The HEPA filter media has a lifespan of 8-12 months, and the activated carbon adsorption layer can be regenerated periodically. The annual filter media cost per unit is only about 1000 yuan, a 40% reduction compared to traditional equipment. Furthermore, the equipment body is made of stainless steel, which is corrosion-resistant, easy to clean, and can operate stably even in humid workshop environments, reducing maintenance costs.

III. Application Results: From "Problem Workshop" to "Benchmark Workshop"

After 12 KNOKOO FES600 fume extractors were put into use at the processing plant, the workshop environment was completely transformed in just one week, and various production indicators improved simultaneously. Specific results are as follows:

- Significantly Improved Product Quality: Welding fume particles no longer adhere to the surface of hardware parts, reducing product cleaning costs by 30%, and the scrap rate dropped from 15% to 2%, directly reducing economic losses by nearly 80,000 yuan per month.

- Employee Health Guaranteed: The fume concentration around the welding stations in the workshop dropped to 0.2 mg/m³, meeting occupational health standards. Employee respiratory discomfort symptoms completely disappeared, and team stability was significantly enhanced.

- Zero Environmental Compliance Risk: During a surprise inspection by the local environmental protection department, all indicators of the company's exhaust emissions were better than the standards, earning the department's approval and completely eliminating concerns about fines and production shutdowns.

- Steady increase in production efficiency: The clean and quiet workshop environment allows employees to focus more on their work. In addition, the equipment has fewer malfunctions and is easy to maintain. The daily output of the 12 welding stations has increased by 12%, and production efficiency continues to improve.

IV. User Testimonials: Choosing the Right Equipment is More Effective Than Spending Money on Upgrades

During a follow-up visit, the manager of the processing plant remarked, “Previously, to solve the smoke problem, we tried exhaust fans and simple air purifiers, spending a lot of money without any effect. Employees complained, customers were dissatisfied, and there was environmental pressure; we were really overwhelmed during that period. We chose the KNOKOO FES600 with a try-it-and-see attitude, but the results were amazing! Not only is the smoke gone, but product quality and production efficiency have also improved. Now our workshop has become a benchmark for our peers in the surrounding area. This money was well spent!”

V. Solution Insights: Precision Welding Smoke Purification – Focus on the Dual Core of “Capture + Purification”

The core of smoke purification in precision welding scenarios lies in “both effective extraction and thorough filtration.” The KNOKOO FES600 fume extractor solves the source problem with “360° precise capture” and overcomes the filtration challenge with “four-stage deep purification,” while also offering advantages such as energy saving, intelligence, and low cost, perfectly meeting the needs of precision machining enterprises.

Whether you're in the new energy vehicle parts, medical device, or precision electronics industry, and you're facing welding fume problems, KNOKOO can provide customized fume purification solutions based on your number of workstations, welding types, and workshop layout. Contact KNOKOO now to let the FES600 fume extractor "remove smoke and reduce harm" in your workshop, creating an environmentally friendly, healthy, and efficient production environment, and laying a solid foundation for your business development.