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case<br />
study<br />
Capturing Welding Fume/Smoke at Toyo Seat USA<br />
Product Information<br />
Product: Gold Series ® dust collector<br />
Size: (2) GS12 “Low Boy” Models<br />
Air Volume: 9,000 cfm<br />
Application: Weld Fumes<br />
Customer: Toyo Seat USA Corporation<br />
Installation date: October 2011<br />
Challenge<br />
Toyo Seat USA Corporation in Imlay, Michigan is an<br />
award winning automotive seating manufacturer. They<br />
are known for their unique production system that enables<br />
them the flexibility to respond quickly and appropriately to<br />
their customer’s urgent needs. <strong>This</strong> frequently requires<br />
movement, rearrangement and set up of numerous robotic<br />
weld cells used during the production process. Over the<br />
past 10 years, each independent weld cell had its own<br />
individual dust collector that sat on top of it. As the years<br />
passed, issues started to arise.<br />
Having the dust collector directly above the robotic weld<br />
cell resulted in sparks being sucked directly into the dust/<br />
fume collector unit, frequently resulting in fires. Mobility<br />
turned into a concern. When a weld cell was required<br />
to be moved, it would be a time consuming and tedious<br />
process because of the top mounted dust collectors. Having<br />
to do maintenance on top of the collectors was another<br />
issue. With the collectors on top of the weld cell and with<br />
no platform, a lift would have to be used for filter change<br />
out. The energy to run numerous blowers and produce<br />
compressed air for each dust collector was noticed and<br />
adding up.<br />
© <strong>Camfil</strong> Farr <strong>APC</strong><br />
<strong>This</strong> case study is available<br />
to view as a video on<br />
www.camfilfarrapc.com<br />
in the <strong>APC</strong> Video Center.<br />
Robotic weld cell at Toyo Seat USA.<br />
Weld fumes from robotic welder.<br />
weld fumes
Two Gold Series ® GS12 dust collectors installed at Toyo Seat USA on weld fume/smoke application.<br />
Weld cells with individual hoods and ducting for mobility.<br />
© <strong>Camfil</strong> Farr <strong>APC</strong><br />
<strong>Camfil</strong> Farr <strong>APC</strong><br />
3505 Airport Road<br />
Jonesboro, AR 72401<br />
www.camfilfarrapc.com<br />
Email: filterman@farrapc.com<br />
Solution<br />
Chuck Pratt, Toyo Seat’s maintenance supervisor did<br />
an online search for a solution, and ultimately contacted<br />
Kevin Tucker, <strong>Camfil</strong> Farr <strong>APC</strong> sales engineer. Chuck<br />
discussed some of the issues they were experiencing<br />
and the expectations that they were looking for. Kevin<br />
contacted Fred Marshall with <strong>Camfil</strong> Exfil and together did<br />
an on-site, hands-on demonstration of the Gold Series ® for<br />
Chuck, Dan Serwich the plant manager, and J.B. Nishimiya<br />
the process engineering manager. Using the Gold Series ®<br />
demo trailer unit, they explained the features and benefits<br />
of the collector right at the customer’s site. A walk-through<br />
to see the current systems and requirements and then a<br />
costing analysis were done to address the true total cost of<br />
ownership.<br />
A central system was designed, consisting of two GS12<br />
Low Boy dust collectors. Installed side by side, each<br />
collector is rated for 9,000 CFM at a 2.3:1 A/C ratio. The<br />
Gold Series ® Low Boy would stay under the ceiling height<br />
requirement that was needed. Ducting would run out and<br />
branch off to a total of 18 robotic weld cells. Each hood<br />
was equipped with a spark arrestor to prevent sparks from<br />
entering the system. Mobility was returned to the customer<br />
using the central system layout design. “Now all we do is<br />
pull a couple of pins, undo a couple of clamps, remove the<br />
hood, and move it where we want to move it. It’s nice,”<br />
says Chuck Pratt, Toyo Seat maintenance supervisor.<br />
As an extra safety precaution the optional fire sprinkler<br />
system was added inside each dust collector as well as<br />
flame retardant HemiPleat Gold Cone filters. To save<br />
on the energy costs, a VFD (Variable Frequency Drive)<br />
controller was used. With the Gold Series ® collectors<br />
and options operating in place, Toyo Seat will save over<br />
$30,000 a year according to Dan Serwich.<br />
For further information regarding this application, contact <strong>Camfil</strong> Farr <strong>APC</strong> Rep Fred Marshall with <strong>Camfil</strong> Exfil at 734-261-1860.<br />
Phone: 870-933-8048<br />
Fax: 870-933-8381<br />
CAsE sTudy / PAGE 2<br />
“ I would definitely recommend the Gold Series dust and fume collection unit”<br />
says Dan Serwich, Plant Manager, Toyo Seat USA, Imlay, MI<br />
032312
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