MNP Corp. Clears the Air in Boltmaking Plant

Routine use of cold headers and boltmakers at the MNP Fastener and Highland Bolt Divisions of MNP Corp. generated such heavy smoke and oil mist that, on some days, a worker could lose sight of their hand if they held it over their head. Although health authorities determined that the smoke did not pose a health risk, the company recognized the safety concerns and lower employee morale associated with poor visibility throughout the plant.

MNP’s Highland Bolt Division had the largest number of high-speed boltmakers in the United States, specializing in the cold heading of bolts at its Utica, Michigan, plant. The plant’s primary products were hex bolts used by the automotive and distributor markets.

The raw material used to manufacture these bolts was coated with an oil lubricant. As the material was processed through the various cold-forming operations in high-speed boltmakers, considerable heat was generated. This produced extremely heavy oil smoke and mist that spread throughout the plant.

Finding a Solution to Heavy Oil Smoke

Although the smoke had been a continuing problem for MNP Corp., the company had been unable to find an effective solution.

During the summer, exhaust fans were used to draw the smoke outdoors. However, this approach was not practical year-round. During the winter, employees would often turn on the exhaust fans simply to obtain temporary relief from the visibility problems caused by the smoke.

MNP Corp. recognized that the smoke was not only an irritation to employees but also contributed to increased heating costs. Exhausting heated indoor air outside meant that additional energy was required to heat replacement air.

In 1982, MNP Corp. committed to solving the smoke problem. Tom Klein, Plant Manager, began the process by consulting with several companies specializing in fans, air cleaners, and related equipment.

Because of the plant’s internal layout, MNP Corp. presented some unusual challenges to air-cleaning equipment manufacturers.

Capturing Smoke From 11 Boltmakers

Heavy smoke was being generated by 11 separate boltmakers in the plant. Because these machines could not be enclosed, any effective solution would require a custom-designed duct system to capture the smoke produced by each machine.

The specialized ductwork requirements discouraged several potential suppliers. However, a sales representative for SMOG-HOG® Industrial Air Cleaners prepared a proposal for a custom system while working with another company that specialized in designing and building unique ductwork systems.

The proposal called for the installation of 11 SMOG-HOG SH-40-PE-S-EF industrial air cleaner cart-mounted units, each rated at 4,300 CFM. One SMOG-HOG was ducted to each smoke-producing machine.

The proposal also included a mobile ELECTRO-FOAMER cart-mounted cleaning system manufactured by United Air Specialists, Inc. in Cincinnati, Ohio.

Unlike the other bidders, United Air Specialists guaranteed that the 11 SMOG-HOG units would solve the smoke problem generated by the machines.

The proposal was accepted, and the 11 units were installed in 1984.

Expanding the System to Capture Additional Smoke

Once the SMOG-HOGs were installed and successfully removing the smoke generated by the 11 machines, Klein noticed that some smoke was still entering the 120,000-square-foot plant from other sources.

He discovered that 18 cold headers on a nearby production line were still generating a noticeable amount of smoke. The plant manager determined that these machines were responsible for approximately 30% of the smoke that had been present in the plant before the original SMOG-HOG installation.

Having confidence in the system, Klein asked United Air Specialists to develop a plan to address the remaining smoke.

This time, a different approach was used. Instead of installing an individual air cleaner on each machine, the system was designed around one large centralized air-cleaning unit ducted to all 18 cold headers.

Maintenance Was Critical to Long-Term Success

The 11 original SMOG-HOG units were cleaned weekly using the mobile ELECTRO-FOAMER system. The cart-mounted cleaning system could be moved throughout the plant to service each unit on a regular schedule.

The system was designed to make routine maintenance relatively simple. This was particularly important to Tom Klein, who understood that even the best air-cleaning equipment will eventually stop performing if it is difficult to maintain.

As Klein explained, “The only way the equipment will be properly maintained is if it’s easy to do.”

The centralized unit originally had an automated self-cleaning system that was programmed to complete a cleaning cycle each week without worker intervention. According to Klein, the simplicity of the maintenance process was an important factor in the long-term success of the system.

Note: The original self-wash system is no longer in use. Today, Bee Clean Specialties provides maintenance and service for the air cleaners.

Results: Cleaner Air and Recovered Lubricant

The SMOG-HOG installation produced the expected benefits, including:

• Improved working conditions
• Better visibility throughout the plant
• Improved employee morale
• Increased productivity
• Reduced winter heating costs
• Recovery of valuable lubricant

One particularly valuable benefit was the ability to recover approximately 1½ quarts of lubricant per day from each of the 11 original SMOG-HOG units. The recovered lubricant could then be reused in the cold-heading process.

Klein was extremely satisfied with the performance of the industrial air-cleaning system. He was also impressed with the responsiveness of the sales and service teams, noting that they went out of their way to complete the project correctly and quickly.

Maintaining SMOG-HOG Systems Today

The original MNP Corp. case study demonstrates an important lesson that remains true today: proper maintenance is essential to the long-term performance of an electrostatic air-cleaning system.

SMOG-HOG systems can collect significant amounts of oil smoke and mist from demanding manufacturing processes such as cold heading and boltmaking. However, collection cells, ionizers, prefilters, and other components need to be cleaned, inspected, and maintained regularly to keep the system operating effectively.

While the original self-cleaning equipment described in this case study is no longer in use, Bee Clean Specialties now maintains the air cleaners. Our technicians service SMOG-HOG® systems and other electrostatic air cleaners throughout our service areas, helping manufacturers keep their equipment operating properly.

For manufacturers dealing with oil smoke from cold headers, boltmakers, CNC machines, grinding operations, or other industrial processes, proper air filtration and ongoing maintenance can make a significant difference in air quality, productivity, and operating costs.

If your SMOG-HOG® system needs cleaning, repair, replacement parts, or ongoing maintenance, contact Bee Clean Specialties at 888-451-0844.

Source: Parker Case Study, 1982