A Clear View with Filtermist

Crittall Windows, a world-renowned manufacturer of steel windows, doors, and screens, caters to a variety of architectural needs, from modern residential buildings to historically significant structures. Based in Essex, the company has been a pioneer in its field since 1849, blending tradition with cutting-edge technology to maintain its position as an industry leader. With such a rich history, including producing windows for the Titanic and manufacturing bridges during World War II, Crittall Windows continues to innovate. Its latest advancements include modernising its machining department with the help of Filtermist’s FX Series oil mist collection systems, a decision that has profoundly impacted the working environment and efficiency of its operations.

As part of Crittall’s ongoing investment in new technologies, the company has undergone significant upgrades in its machining division. Darren Joyce, Production Director at Crittall, explains: “We are transitioning from old machinery that was designed for bulk production to more flexible CNC machines. Our customers require more bespoke, one-off pieces rather than hundreds of identical components, so we’ve moved to CNC machining to adapt to these demands.” While this transition has allowed for greater flexibility and precision, it also introduced new challenges, particularly concerning oil mist and fumes generated during the machining process.

Steel, unlike materials such as aluminum or PVC, requires longer machining times and extensive use of coolants. This led to a buildup of oil-laden fumes, creating an uncomfortable and potentially hazardous environment for the factory workers. Joyce recalls: “The factory began to mist up, and it wasn’t a good environment for our employees. Plus, excessive coolant on the parts created additional fumes during downstream welding processes.”

Crittall sought a solution that would address both the air quality concerns and the excess coolant issues. That’s when Filtermist stepped in with its FX Series oil mist collection systems. “We needed a way to remove the oil from the air inside the machines so that when the doors open, the oil-laden air doesn’t escape into the workshop,” says Joyce. After extensive research, the team found that Filtermist’s centrifugal systems were the perfect fit for their needs.

The Filtermist FX5002, now installed in all of Crittall’s CNC machines, uses centrifugal force to extract oil mist from the air, effectively filtering it out before it has a chance to escape. According to Joyce, the system has exceeded expectations: “We thought it sounded too good to be true, but it works! We’ve even gone a step further by modifying the system to recycle the collected oil, using it in our flood-based coolant machines and significantly extending the life of the oil.”

The improvements didn’t stop there. Crittall has also introduced energy-saving measures, such as automatic shutdowns for machines that have been idle for 10 minutes, reducing unnecessary energy consumption. “We’re delighted with Filtermist,” Joyce says. “It’s a fantastic product that does exactly what it says on the tin.”

In less than a year, Crittall has installed 12 FX5002 units and equipped them with Filtermist’s F Monitor 2, a smart monitoring system that provides live readings of the units’ efficiency. The system alerts staff when maintenance or service is required, ensuring that the units continue to operate at peak performance.

Compact and easy to install, the FX5002 model boasts an airflow rate of 2000m³/hr and is powered by an efficient 1.5kW motor, making it a reliable and space-saving solution for facilities with limited room. At just 613mm tall (751.5mm with an after-filter unit), the FX5002 can fit into most factory environments without taking up too much space.

The introduction of Filtermist systems has had a measurable impact on the working conditions at Crittall. “Shortly after installation, we noticed the mist clouds dissipating,” Joyce recalls. “The health and safety of our employees has always been our top priority, and the Filtermist systems have made a huge difference. There’s no longer any oil on employees’ clothes, hands, or faces, and it’s not on the floors or workpieces either. The workplace is cleaner, safer, and much more pleasant.”

In addition to the improvements in air quality and worker safety, Crittall has also seen significant economic benefits from installing the Filtermist systems. Recycling the collected oil has reduced coolant costs, and the automatic start/stop function of the units has led to noticeable energy savings. “We’ve cut down on oil consumption, reduced costs, and improved air quality,” Joyce explains. “It really is a no-brainer.”

As Crittall Windows celebrates its 175th anniversary, the company is demonstrating that even with such a long and storied history, there is always room for innovation. By investing in advanced technologies like the Filtermist FX5002, Crittall is not only improving its production processes but also creating a safer, more efficient workplace for its employees.

For a company with such a rich heritage, the future looks just as bright, and Filtermist’s solutions are helping to ensure that Crittall remains a leader in its field for years to come.