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Q: What applications was the MistBuster actually designed for? A: The MistBuster 500 is an electrostatic industrial air cleaner mist collector product designed specifically for the filtration of coolants, oil mist and smoke from today's modern machine tools. The use of metalworking fluids can pose a serious health threat to the employees in the metal working industry and is a priority focus of OSHA. Top Q: How easy is the MistBuster 500 to install? A: The MistBuster is easy to install and includes a 10’ power cord so that it can be installed without an electrician. Royal Filtermist and Aercology centrifugal require an electrician to hard wire power and controls. Both units always require some sort of mounting hardware. The MistBuster has an inlet opening that is 16” x 9”. This inlet opening can be set over any hole in the top of the machine tool that is 6” in diameter. If you cannot provide an inlet opening on the top of the machine tool, we can use our plenum with machine mount stand, pedestal stand or ceiling hanging kit. This easy installation makes it very easy for AQE to offer a 30-day performance guarantee. If the customer needs to hire an electrician, a free trial will cost them a few hundred dollars. We have made it very easy for you to realize how easy it is to install the MistBuster 500 by posting the installation manual that comes with this mist eliminator air cleaner. Top Q: How many years is the manufacturer's warranty? A: Three-year manufacturer's warranty. Top Q: What machine tools has the MistBuster been installed on? A: The MistBuster has been installed on many industrial machines some of them include but are not limited to; Acme Eurotech Leblond-Makinu Ameka-Seki Ex-Cell-O Matsuura Bridgeport Fadal Mazak Brown & Sharp Haas Mitsubishi
Nakamura-Tome Citizen Hydromat Niigata Cutting Edge Tech KAO Ming Ohmiya Daewoo KIA Okuma DoAll Chiron-America
Kitamura Star Eubama Leadwell Tsugami Hardinge Miyano Cincinatti Centerless Hitachi Seiki Mori Seiki Cincinatti Milacron Huron
For a visual to see examples of MistBusters mounted on / to these machines please Top Q: What are the main differences between the MistBuster and the "Fog Pig" that I keep hearing about? (note: we have chosen not to use the direct trademark name of this particular mist collector... if you don't get it, give us a call and we'll give you more obvious hints) .
A: First of all, the MistBuster is machine mounted so that it is not exposed to the airborne dust and dirt that mixes with the mist on background EAC systems. Once the cell collects dust and oil, drainage is less fluid. The "Fog Pig" has to be cleaned much more frequently than the MistBuster to maintain its efficiency. Secondly, the MistBuster has 4” of mechanical impingement as compared to most EAC’s that have only a 1” prefilter. This keeps most of the large mist droplets and metal chips and turnings out of the main EAC. Finally, the variable speed controller allows the MistBuster to run the minimum amount of airflow to create negative pressure. This is the main feature in creating a long maintenance interval. This also has a dramatic effect on efficiency. Top Q: What are the names of some companies who use MistBusters on their industrial machines? A: We have all types of companies who have made the MistBuster series a part of their oil smoke and coolant mist air cleaning solution. A few of the larger corporations include; Boeing (West Coast) General Motors (New York) Masco Tech (Michigan) - Supplier to the auto industry, currently has 42 units and has committed to purchasing 20 more this year. Remmele (Minnesota) - 100 million-dollar micro machining job shop for the medical industry. Boston Centerless (Massachusetts) – Supplies materials to major job shops like Remmele. Q: How noisy is the MistBuster and how much vibration does it cause? A: The MistBuster is quiet and vibration-free. The MistBuster series uses a high quality motorized impeller imported from Germany that is dynamically balanced and suspended from rubbe isolation mounts. The impeller is mounted on the clear air side which means there is no buildup of contaminants on the moving part.
Remmele Engineering purchased MistBusters for their machine tools that use drills the diameter of a human hair to drill holes in a part that has to be magnified many times to be seen with the human eye. They could not afford any vibrations and were looking for a vibration FREE solution to their oil smoke and mist problems. Remmele Engineering tested the MistBuster and found it to be perfect for their application. They purchased 25 plus MistBusters and directly mounted a MistBuster to each machine tool in their facility. A by-product of having a variable speed controller is that the slower you run the MistBuster, the quieter it is. Top Q: I am concerned that I need a higher CFM rating to handle the out-put of air contamination that my machine tool produces... will 500 CFM be strong enough to handle my high pressure machine tool mist? A: The MistBuster has a variable speed controller so that you can control the amount of air being sucked out of the machine tool enclosure. Excessive airflow causes excessive amounts of mist-laden air to be removed from the machine tool enclosure. This shortens the life of disposable filters in units like the Torit Dryflow and increases the amount of maintenance for centrifugal units. All that is needed is negative pressure within the machine tool enclosure to handle any oil smoke and coolant mist problem, nothing more.
There is a misconception in the machining industry that more airflow is desirable, bigger is better. That is why Med-Source went with the 800 cfm Dryflow instead of the smaller model Torit rated at 390 cfm for their small Swiss lathes. MistBusters were replaced with these Torrit 800-cfm units with the 500-cfm MistBuster running on a quarter speed. All that is needed is negative pressure so that the mist and smoke that are generated does not escape the machine tool enclosure. The MistBuster does not allow the mist and smoke to build up and there will be no cloud to hit the operator in the face when he opens the door. one can use a bathroom fan as a good analogy when explaining the benefits of using the MistBuster's lower CFM rating; most of bathroom fans are only rated betweeen 75-125 cfm. These fans generally keep the steam from building up within the room and escaping into adjoining rooms. Most bathrooms are larger than a machine tool enclosure. Why did Med-Source need an 800-cfm fan on a small enclosure? The answer is they did not, all they needed was about 125 cfm. Top Q: How often do I have to clean the MistBuster? A: Very low maintenance, almost totally self-cleaning. (Typically in an oil-based fluid, maintenance is once or twice a year; for a water-based coolant, maintenance is 1-3 times per year.). Cleaning is very simple. Dip the filters and cell in alkaline detergent and rinse with hot water; let dry and return to the MistBuster. Many shops have parts washers that can be used as long as the washing fluid is noncorrosive to aluminum.
Remmele Engineering operates their facility 24 hours a day, seven days a week. They typically clean their units once per year. Other customers have had to clean their MistBusters two to three times per year. Because the MistBuster has a variable speed controller, the MistBuster can operate at very low air speeds. This allows the metalworking fluid to drain back into the machine tool while the MistBuster is in operation. Water-based coolant can evaporate leaving solids dried onto collection plates on the cell and prefilters. If the MistBuster is used continuously, its filtration system remains wet and there is a longer maintenance interval as opposed to intermittent use. There is no evaporation with oil-based metalworking fluid so the MistBuster can go a year or longer without having its cell cleaned. Top Q: What are the positives and negatives of using the MistBuster vs. a disposable media mist collector? A: Media mist collection involves using low velocity impaction and filtration technology. Very high efficiencies are possible using media filtration however they often plug up and restrict air flow. Eventually this high restriction leads to needless fan noise (like a big shop fan). Periodic filter replacement is required and their replacement, disposal and associated labor can be costly. Over time the cost to run these units can absorb as much as 2100 watts to operate and can be an additional drain on resources. Top Q: What are the main differences of using the MistBuster vs. a centrifugal mist collector? A: Centrifugal mist elimination involves a high velocity / high energy process where the impeller accelerates large drops and the inertial separation and impaction removes large drops. Centrifugals have been known for not being able to collect smoke or fine droplets. It actually creates fine droplets by breaking up large drops in the high energy acceleration process that causes a very high siren like screech. Centrifugal mist eliminators require frequent cleaning to remove accumulated mist and dust that causes impeller imbalance. Imbalanced impellers cause machine tool vibration and loss of precision and frequent cleaning and maintenance is required to avoid imbalance. Centrifugals can also take upwards of 2100 watts to operate. Top See the complete line of Coolant oil mist collectors eliminators & separators, MistBuster 500 coolant oil mist collector & eliminator or all industrial products.
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