Robotic Welding Fume Extraction Case Study For a Tier 1 Automotive Supplier

When a Tier 1 automotive supplier relocated a robotic welding line, the clock was ticking. 

The company had less than four weeks to design, deliver, and install a complete robotic welding fume extraction system for their new galvanized steel welding operation - all while maintaining production schedules and ensuring clean air from day one.

The challenge was intensified by the nature of the work: welding galvanized and oil-coated automotive components produces dense fumes containing zinc oxide and oily particulates that can quickly compromise air quality and equipment performance. With smoke and fumes already presenting challenges at the previous facility, the customer needed a proven partner to deliver a reliable solution quickly.

Rather than risk delays with an untested vendor, the automotive giant turned to A.C.T. Dust Collectors - a trusted partner already protecting air quality at their other facilities.

The Challenge: Galvanized Smoke & Tight Timelines

Welding galvanized, oil-coated stampings creates a tough mix of emissions. The arc vaporizes the zinc layer, producing dense galvanized welding fumes made up largely of zinc-oxide particulate. At the same time, residual cutting oils flash into a light hydrocarbon mist that clings to dust and accelerates filter loading. Together, these streams can push fume concentrations past OSHA’s zinc-oxide limit of 5 mg/m³ if capture velocities drop even briefly.

Because OSHA 1910.252 and related ventilation rules require that welding fumes be kept within safe limits, the customer’s team had to restore compliant airflows the moment the line went live. Missing the four-week move window would have meant holding production - and jeopardizing manufacturing air quality targets tied to customer contracts.

In short, the project demanded a purpose-built OSHA indoor air quality solution that could:

• Arrive in < 4 weeks and mate with an existing robotic cell
• Capture fine welding smoke collection streams before they spread through the plant
• Handle sticky oil mist without premature filter change-outs
• Provide clear sizing data so management could sign off on capacity for future expansion

Operations teams facing similar relocations will recognize the same clock: production commitments, compliance paperwork, and the need for an industrial dust collection system that simply works from shift one. That urgency set the stage for choosing A.C.T.’s ACT 3-36 collector as the core of the welding fume solution.

The Solution: ACT 3-36 + On-Site Engineering

Having successfully used A.C.T. Dust Collectors at other locations, the customer again chose their trusted partner. A.C.T.'s engineering team immediately mobilized to the existing facility to:

• Measure existing welding cell dimensions and layout
• Calculate specific airflow requirements and CFM specifications for optimal capture
• Assess ductwork routing possibilities for the installation
• Design a system optimized for galvanized welding smoke collection

Based on the application requirements and facility layout, the engineering team specified the ACT 3-36 dust collector. This heavy-duty cartridge collector was selected for its proven reliability in demanding welding environments and its ability to handle the high particulate loads generated by galvanized steel welding. Its MERV 15 efficiency rating, venturi-assisted pulses, and quick-lock doors made it an ideal solution to cut maintenance hours and protect sensitive robots from particulates.

The model was in the “Ready to Ship” products, allowing delivery to the customer in 23 days - well inside the four-week mandate. The customer's maintenance team handled the installation with comprehensive technical guidance and support from A.C.T.'s engineering staff.

The Results: Clean Air, Long Filter Life, and Zero Downtime

Commissioned in November 2023, the ACT 3-36 collector went from purchase order to full production in just under four weeks - matching the schedule the plant set for its relocated welding line. Eighteen months later (June 2025), the unit is only running one (sometimes two) shifts a day on its original cartridge set. Static pressure has crept only from 1.7 to about 2 inches wg, a change small enough to confirm that airflow, pulsing, and media loading remain squarely in the design window - no capacity loss, no need to throttle back robots, and no filter change-outs on the maintenance log.

Project Success Metrics:

• Delivered and operational in under 4 weeks as promised
• Welding fume issues were effectively eliminated from day one
• Zero production downtime due to dust collection system issues
• System performance has exceeded initial design expectations

Installation Experience and Customer Collaboration:

Despite choosing a self-installation approach to meet their aggressive timeline, A.C.T. remained deeply involved throughout the project. The collaboration included:

• Pre-installation planning sessions to align system design with plant capabilities
• Detailed installation drawings and technical specifications
• Post-startup system verification and optimization

This collaborative approach ensured that even with in-house installation, the system met all performance targets and operational requirements. The result was a seamless deployment that maintained the four-week timeline while delivering professional-grade results.

Following A.C.T.'s timely delivery and exceptional technical support, customer’s management team praised the results: "Fast, predictable, and bullet-proof - A.C.T. hit every mark and delivered exactly what we needed." The success of this welding fume solution demonstrates how proper engineering and quality equipment deliver sustained value.

Why A.C.T. Was the Preferred Choice

Being savvy and foresighted, the customer didn't request competitive bids for this project. Wondering why? Previous experience had already proven A.C.T.'s ability to deliver accurate system sizing, fair pricing, and reliable long-term performance. The customer saw no value in delaying the project to evaluate alternatives when they already had confidence in A.C.T.'s capabilities.

This trust-based relationship reflects A.C.T.'s approach to customer partnerships - delivering consistent results that eliminate the need for customers to continuously shop for vendors. 

Smart Design. Fast Delivery. Long-Term Results.

A.C.T. Dust Collectors proved once again that effective industrial dust collection requires more than just equipment - it demands experience, hands-on engineering expertise, and flawless execution. By combining rapid response with proven technology, A.C.T. delivered a robotic welding fume extraction solution that met every requirement and timeline.

This project success demonstrates how the right partnership can turn a challenging timeline into a competitive advantage, ensuring clean air and uninterrupted production from day one.

Looking for a reliable solution to your welding fume challenges?

Contact A.C.T. Dust Collectors today to discuss your robotic welding fume extraction needs. Our engineering team is ready to deliver fast, reliable results that keep customer’s production lines running clean.

Request a quote and discover how A.C.T. can solve your manufacturing air quality challenges.