A major industrial casting manufacturer located in Brewster, New York, contacted Air Purifiers, Inc. to develop a solution for persistent smoke, oil mist, and airborne haze generated by its casting and molding operations.
Project Completion: August 2026
System Manufacturer: Airflow Systems
Equipment Installed: Three Airflow Systems MP8 Mist & Smoke Eliminators
Application: Industrial Casting Machines, Mold Operations & Oil Mist Control
System Design & Installation: Air Purifiers, Inc.
A major industrial casting manufacturer located in Brewster, New York, contacted Air Purifiers, Inc. to develop a solution for persistent smoke, oil mist, and airborne haze generated by its casting and molding operations.
The manufacturing process produced airborne contaminants that migrated beyond the immediate casting machines, creating a noticeable haze throughout the production facility. These contaminants were also entering the building’s heating, ventilation, and air conditioning (HVAC) systems, creating additional concerns related to air quality and equipment contamination.
The manufacturer needed an effective air filtration solution that would capture smoke and oil mist directly above the production equipment without interfering with the loading, unloading, or operation of its casting machines.
Industrial casting operations can generate significant quantities of smoke, oil mist, and fine airborne contaminants, particularly during mold processing and the application of release agents and other process materials.
At this facility, emissions from both manually operated and automated casting equipment were spreading throughout the production area, resulting in visible airborne haze.
The contamination was not limited to the manufacturing floor. Oil mist and smoke were also being drawn into the facility’s HVAC system, potentially contributing to filter loading, contamination of internal components, and increased maintenance requirements.
A primary challenge was the physical arrangement of the casting equipment. The machines required unobstructed access for loading and unloading molds and finished castings, making conventional extraction hoods and ductwork difficult to position.
The solution needed to effectively capture airborne contaminants while maintaining full accessibility to the casting equipment and preserving normal production operations.
After evaluating the manufacturing processes, equipment layout, and operational requirements, Air Purifiers designed and installed a localized air filtration system utilizing three Airflow Systems MP8 industrial mist and smoke eliminators.
The MP8 units were strategically positioned above the casting equipment to capture smoke and airborne oil mist as the contaminants rose from the manufacturing process.
The installation consisted of:
- One Airflow Systems MP8 positioned above a manual casting operation where mold processing and material application generated airborne smoke and mist.
- Two Airflow Systems MP8 units installed above automated casting machines to capture emissions during continuous production operations.
Careful consideration was given to the location and mounting of each air cleaner. Air Purifiers positioned the units to provide effective contaminant capture while maintaining the necessary clearances for machine loading, unloading, and operator access.
By locating the filtration equipment directly above the emission sources, the system was able to capture smoke and oil mist before they dispersed throughout the manufacturing facility.
This localized filtration approach also helped prevent airborne contaminants from migrating into the building’s HVAC system.
The completed installation successfully addressed the manufacturer’s airborne smoke and oil mist problems, eliminating the visible haze that had previously spread throughout the production facility.
By capturing contaminants directly above the casting machines, the three Airflow Systems MP8 units significantly improved the manufacturing environment while reducing the migration of oil mist and smoke into the facility’s HVAC equipment.
Equally important, the carefully engineered placement of the filtration units allowed both manual and automated casting operations to continue without interference from the extraction equipment.
The result was a cleaner production environment, improved control of airborne contaminants, and reduced exposure of the building’s HVAC systems to process-generated oil mist.
This project demonstrates Air Purifiers’ ability to develop customized industrial mist and smoke filtration solutions for challenging manufacturing applications where effective contaminant control must be balanced with equipment accessibility and production efficiency.
