Case Study: Innovative Welding Fume Control in a State-of-the-Art Manufacturing Facility

The Challenge: Managing Welding Fumes in a Large-Scale Fabrication Facility

A new 61,000 square foot manufacturing facility needed a reliable air quality solution to handle heavy-duty welding on large modular electrical control enclosures and skid fabrications. Traditional source capture arms were impractical due to the scale of the workpieces, and an ambient system would have been inefficient in the expansive building. Adding complexity, many welding tasks took place inside enclosures, where smoke could quickly build up and compromise safety.

Smart Solution: Powerful Capture and Hose Reels with Automated Control

Glacier Technology provided a custom source capture weld fume solution using PlymoVent hose reels paired with an Imperial Systems CMAXX collector. This was the first installation to combine hose reels with magnetic hoods, allowing welders to easily position fume capture exactly where it was needed, even inside metal framing.

The system was designed with automation in mind. As additional hose reels (eight total) were deployed, the variable frequency drive (VFD) increased fan speed to match demand. When fewer reels were in use, or when they were retracted, the system automatically reduced speeds. This intelligent control minimized energy use while ensuring consistent protection.

Why This Approach Worked

• Effective Source Capture: Hose reels brought the collection point directly to the welders, eliminating exposure in the breathing zone.
• Adaptive Efficiency: Automatic VFD adjustments balanced airflow and reduced energy waste.
• Operator-Friendly: Magnetic hoods made placement simple, especially when welding in challenging positions or inside enclosures.
• Compliance and Safety: The system kept the shop floor free of lingering smoke, supporting OSHA standards and protecting worker health.

Results: A Clean, Productive Shop Floor

The project was completed on time and under budget. Once operational, the facility achieved its goal of a smoke-free environment. Welders reported clear visibility and a noticeable reduction in breathing-zone exposure. Facility managers gained confidence that air quality was under control without costly downtime or complicated maintenance demands.

Lessons for Facilities Managers

For engineers and facilities managers, this project highlights the value of flexible, automated fume control:

• In environments where welding involves large structures or enclosures, hose reels can outperform traditional arms.
• Automated fan speed adjustments reduce operating costs without sacrificing performance.
• Designing with worker usability in mind—like magnetic hood placement—ensures the system is actually used as intended.
  

Proven Solutions for Complex Airflow Challenges

This case study shows how the right combination of equipment can solve even the toughest welding fume challenges. Glacier Technology partners with leading manufacturers to deliver custom solutions, helping facilities maintain compliance, protect workers, and keep operations running smoothly. Contact us to discuss your project.