One of New York State’s largest boiler manufacturers contacted Air Purifiers, Inc. to develop a solution for welding smoke and airborne contaminants accumulating throughout its manufacturing facility in Troy, New York.
Project Completion: October 2026
System Manufacturer: Airflow Systems
Equipment Installed: 24 G101 Industrial Air Cleaners
Total Air Filtration Capacity: 72,000 CFM
System Design & Installation: Air Purifiers, Inc.
The facility performs extensive welding and metal fabrication on large industrial boiler assemblies. These operations generate significant amounts of welding fumes, smoke, and airborne particulates, creating challenging air quality conditions throughout the production area.
Traditional source-capture ventilation, which collects welding fumes directly at the point of generation, was evaluated but determined to be impractical for this particular manufacturing environment.
The facility utilizes overhead cranes to move large boiler assemblies and components throughout the shop. Additionally, welders and fabrication personnel must continuously reposition themselves around, above, and alongside these large pieces of equipment.
Installing conventional extraction arms, hoods, or fixed ductwork would have interfered with overhead crane operations, material handling, and personnel movement, potentially reducing manufacturing efficiency.
The challenge was to develop an effective air filtration solution that would improve overall shop air quality without disrupting existing production operations.
After evaluating the facility’s layout, manufacturing processes, and operational requirements, Air Purifiers designed an ambient air filtration system utilizing 24 Airflow Systems G101 industrial air cleaners.
Each G101 unit is designed to process approximately 3,000 cubic feet per minute (CFM) of air, providing a combined filtration capacity of 72,000 CFM throughout the manufacturing facility.
Rather than relying on individual source-capture devices, the system was designed to continuously filter the general shop air, capturing airborne welding smoke and particulates as they circulate through the production environment.
Air Purifiers’ installation team strategically positioned and mounted the 24 air cleaners throughout the facility to provide broad coverage of the manufacturing areas while maintaining clearance for overhead cranes, large equipment, and personnel.
The system was designed to complement the facility’s existing manufacturing operations without requiring operators to reposition extraction equipment as work progressed.
The completed installation provides the manufacturer with a facility-wide ambient air filtration system designed to reduce suspended welding smoke and airborne particulate concentrations while preserving the flexibility required for large-scale boiler manufacturing.
By implementing strategically located air cleaners rather than conventional point-of-source extraction, Air Purifiers delivered a practical solution tailored to the facility’s unique production requirements.
This project demonstrates Air Purifiers’ ability to engineer and install customized industrial air filtration systems in challenging manufacturing environments where traditional source-capture methods are not feasible.
