Case Studies

Case Studies

Plexus Corporation

Plexus Corporation Neenah, Wisconsin 3

Plexus Corporation is a leading international company that provides design, manufacturing and testing services to the electronics industry. Plexus has had great success using the Extract-All brand Fume Extraction Systems in two areas.

Wave Soldering

Generally speaking, this unit is used during wave pump and associated parts maintenance. It draws lead solids and lead dust that is generated during the cleaning of various parts. For this application, Air Impurities Removal Systems provided custom downdraft tables.

Solder Pot

Extract-All S-DTL Fume Extractor systems are used on a daily basis to reduce any possible exposure to lead fumes during the drossing of solder pots. By placing the fume extractor arms above the pots, any fumes generated are collected by the Extract-All systems.

Use of the Extract-All systems has dramatically lowered workers exposure levels, and ensures that they are well under OSHA Permissible Exposure Limits.

Husco International

Husco International Whitewater, Wisconsin 3

Husco International, Inc. is a global leader in the development and manufacture of hydraulic and electrohydraulic controls for off-highway and automotive applications.

Husco has a Class 100 Clean room environment where an operator sprays an Isopropyl Alcohol based solution on parts. Their goal was to remove fumes and larger particulates. This was achieved by installing the Extract-All S-984-1 Clean Air Station on the stand where the work is performed. The overspray and fumes are drawn back into the Clean Air Station and are effectively removed by three stages of filtration.

Discovery World

Discovery World 3

Located on the shores of Lake Michigan in Milwaukee, Wisconsin, Discovery World is a 120,000-square foot facility that includes interactive science, technology, and freshwater exhibits, learning labs, theaters, television and audio studios, and fresh and saltwater aquariums. Connecting innovation, science, technology, and the environment with exploration and learning through interactive exhibits and experiential learning programs. They are dedicated to helping people positively impact their communities by developing a better understanding of technology and the environment while fostering both innovation and creativity. *

Discovery World also prides themselves in creating a healthy workplace for their employees by keeping the air in their facility clean. When they purchased their new Mimaki printer, they were researching the best method of evacuating fumes from their print shop room. After considering an ambient or “room air cleaning system”, they decided that the best approach would be to collect the fumes right at the source.

After contacting Air Impurities Removal Systems, Inc. they decided that the appropriate system for their application was the Extract-All S-987-4 Fume Extractor with a 4” diameter inlet, directly connected to the exhaust outlet of the printer. By taking this approach, they were able to collect and filter the active VOC’s by removing both residual dust and solvent fumes. They were able to accomplish this because the Extract-All™ uses multi-stage filtration.

The compact size of the Extract-All® system, the high-efficiency filters, the airflow, and the low noise level were perfect for this particular Mimaki printer.

Discovery World has since turned to Air Impurities Removal Systems, Inc. for additional clean air applications.

The Getzen Company

The Getzen Company 3

The Getzen Company is a brass musical instrument manufacturer that has been family owned for four generations. They create some of the finest instruments in the world and supply products to some of the top musicians in the business. They just celebrated their 70th anniversary in 2009.

In addition to providing top of the line instruments, The Getzen Company prides themselves in creating a healthy work place. So when a recent application required a clean air solution, they evaluated the situation and determined that the best course of action was to provide a filter system to clean the air.

Air Impurities Removal Systems, Inc. helped to create an improved and safer work environment for Getzen’s employees. The sales staff assisted them in selecting an A.I.R. Systems Extract-All S-981-2B Bench-Top Fume Extractor with F-981-1 Filter for their facility. By installing this system in Getzen’s Pro Shop they are able to remove any unwanted impurities from the air. The brazing procedure, in which they join together two materials using a third and heat, gives off a small amount of fumes. The A.I.R. Systems Extract-All System allows Getzen employees to be sure that they are not breathing in any of these fumes.

Beacon Athletics

Beacon Athletics Middleton, Wisconsin 5

Beacon Athletics has been providing high-quality athletic field and maintenance equipment since 1948. In addition to offering their customers top-notch products, they also pride themselves in providing employees with a safe working environment.

Among the various jobs that take place in their Middleton, Wisconsin facility, were two applications that required air purification equipment.

Beacon Athletics Middleton, Wisconsin 6

First, there was a nylon cord-cutting and sealing machine that emitted smoke and fumes. Air Impurities Removal Systems, Inc. provided an Extract-All™ S-987-2A with three-stage filtration, including an adsorption module containing activated carbon. This system removed the smoke and fumes from the air and the worker’s breathing zone.

The second application was a bench-top area where PVC glue was being applied to a product. For this application, an Extract-All™ S-984-1 Clean Air Station was set up on the bench-top. As the glue is being applied, any residual fumes are drawn back, away from the workers breathing zone, into a three-stage filtration system.

By eliminating airborne contaminants from the air, Beacon Athletics has provided a safe and healthy atmosphere for their employees.

Kohler Company

Kohler Company Kohler, Wisconsin 3

World renowned Kohler Co., headquartered in Wisconsin, has been in business for over 130 years, and is a leader in plumbing products, engines and generators, furniture and accessories, and cabinetry and tile.

Over a several month period, Kohler held a Kaizen Event……a focused, intense, short term project to improve the capture and removal of airborne pollutants created by their machining processes.

Testing was done in and around a Brown & Sharpe machine, initially without an air cleaner attached. Testing was then repeated in each location, with five different air cleaning systems.

Results of the readings taken by the Kohler team follow.

Summarily, each air cleaner underwent several tests. The Extract-All E-1400, manufactured by Air Impurities Removal (A.I.R.) Systems, Inc., provided the best results in almost 100% of the test readings.

Subsequently, Kohler replaced numerous existing air cleaners in their machining areas with A.I.R. Systems, Inc.’s Extract-All E-1400 Oil Mist Collector systems. In addition, E-1400’s are specified when new machine tools are installed at Kohler. As a result, they are experiencing cleaner and healthier work environments in their manufacturing facilities.

Milwaukee Public Museum

Project Challenge:

When the conservators at the Milwaukee Public Museum were working on a project in the storage area of the basement that involved organic solvents, they were in need of a cost effective way to protect their health and facilitate the removal of the solvent from the area.

Milwaukee Public Museum 3

Project Solution:

The Extract-All® S-987-2A was selected to support the conservators as they cleaned the museum’s industrial machine collection. The mobility and size of the extraction arms, the flexibility and size of the machine, and the budget conscious cost were perfectly suited for the heavy and cumbersome typewriters and business machines being worked on during this project. The team also recognized the future benefits of the 987 Series for work on other three-dimensional and challenging museum projects.

“The Extract-All 987 received positive reviews from our Industrial Hygienist. The system helped us safely complete our project and will continue to support our work when we are cleaning mummies and other artifacts that can’t be positioned under our laboratory hoods.”

– Christine Del Re
Senior Conservator & Section Head

Milwaukee Art Museum


Chemical Fumes generated by the Art Restoration Process

art restoration

Project Challenge:

The Art Conservation Department of the Milwaukee Art Museum has its own unique history within the walls of the building, including a small location adjacent to a loading dock. Over the years, the size of the workspace, the delicate nature of the work being performed, and fume extraction regulations required the team to find an air cleaning system that was compact enough for the workspace, yet offered a variety of extraction capabilities to support the sensitive conservation process.

Project Solution:

An older model of the Extract-All S-981-2B Bench-Top Fume Extractor was in place for over 20 years while the conservators utilized a variety of small office spaces. After fundraising efforts allowed the team to build a laboratory supported by an extensive fume extraction system, they also upgraded to the current S-981-2B. While the new laboratory and extraction system elevate their capabilities, the portability and flexibility of the 981 Series is better suited for their typical delicate, small-scale projects and allows them to work off-site if the need arises.

“The Extract-All 981 is very quiet, and more importantly, has adjustable suction. It provides a highly focused area of draw that is gentle, giving you total control around delicate and fragile objects. It allows you to adjust right down to the spot you are working on.”

James De Young
Senior Conservator

Portland Community College Sylvania Campus – Air Cleaners for Ceramics Materials

ceramics materials

Before students begin the term and step into a ceramics classroom at Portland Community College’s Sylvania Campus in Oregon, Ceramics Lab Technician Mandy Stigant mixes all the shop glazes. She spends hours during this process, which includes lifting 50-pound bags and filling bins with hazardous materials, exposing her to harmful dust.

The department teaches students about ceramic art, how to hand-build ceramics, how to use fire kilns and how to mix glazes themselves. When mixing dry, raw materials, Stigant uses three air cleaners manufactured by Air Impurities Removal Systems (AIRS) in the mixing room to remove particulates from the air. Never more than two feet away, the cleaners’ extractor arms are positioned directly over the containers where Stigant dumps the raw glazing materials.

Without an air purification system, Stigant and the 500 students who take classes in the ceramics department each year might be at risk for developing harmful health effects. The liability of not having the proper respiratory protection for ceramics workers and students is huge as mixing the glaze involves exposure to oxides, metal colorants and silica, which could cause cancer.

“Silicosis is kind of the most common one that people get if they’re not protecting themselves,” Stigant said. “It’s worse for people than smoking. It’s not just that you’re getting dust particles in your lungs where they don’t belong, but some of these chemicals are toxic in their dry state.”

The Clean Air Solution

The ceramics studio has 130 people in the same room at any time who may be exposed to these chemicals, requiring the college to implement a solution that can extract dust quickly and easily. Using air cleaning systems for dust removal is extremely effective at protecting students from the health effects of dry chemicals for glazing. Stigant employs the Extract-All S-981-2B Bench-Top Fume Extractor. This air purification model includes long extractor arms, a switch-on vent and a cylindrical canister at the top for removing air impurities like dust.

Stigant said even the dustiest part of her job – when she has to cut bags open and dump them into the bins – is no match for the Extract-All 981 system. This air filtration solution can clean up the air filled with dust and potentially cancer-causing materials in two minutes.

Stigant also spoke of the usability of the air cleaners, saying that the machines are simple and effective, and that the extractor arms are long and flexible, which helps to position them wherever she needs them. The Extract-All S-981-2B system offers the college flexibility in more ways than one as the air cleaners are easy to maintain and fix because replacement parts are readily available.

“It’s easy to take the canister off and put a new one on,” Stigant said, “… just a nice feature to have a piece of equipment that’s easy to fix if something starts going wrong. It’s a pretty intuitive machine and well-designed.”

Laser Marking Machine & Color Coding Operation

Based in Brookfield, Wisconsin, Guhring, Inc. is a leading manufacturer of high quality, advanced design cutting tools.

Having spent tens of thousands of dollars over the years for large dust collectors and air cleaning systems, Guhring’s Plant/Facility Engineer Director, Fred Langer, was frustrated. So, Fred decided to find a more economical system that still offered high-quality solutions for smaller applications.

Air Impurities Removal (A.I.R.) Systems, Inc. offered its economical S-987-2A Portable Fume Extractor to handle two of Guhring’s odor-producing operations. Guhring personnel were somewhat skeptical.

Guhring had a fully enclosed, automated laser marking machine and a color-coding operation, both of which produced gaseous fumes. AIR Systems set up its system on a portable caster base, with two inlets. First, one inlet was connected to the exhaust port of the laser marking machine. Next, a self-supporting extractor arm was attached to the second inlet so that the inlet nozzle could be positioned properly. Now, the new system easily draws in fumes from the color-coding operation.

The Extract-All System features three-stage filtration, including a 2-ply polyester panel pre-filter, a refillable adsorption module with activated carbon, and a pleated final filter.

Now, in full operation, Guhring is very satisfied with the Extract-All System’s performance, including its compact design, good suction, high level of filtration, and low maintenance requirements.