In the world of precision craftsmanship, the art of milling plastic in eyeglass lens manufacturing has become a crucial process in providing individuals with clear vision. However, behind the innocuous task lies an invisible danger. It is the generation of fine dust particles that can pose serious risks to both workers and the overall production environment.
Milling plastic eyeglass lenses involves the precision cutting and shaping of materials to meet the unique prescriptions of individuals. This process produces a fine dust particulate. These particles are often invisible to the naked eye. They can contain harmful substances and pose health hazards to workers if proper precautions are not taken.
Health Risks for Workers
Workers involved in the milling process are at a heightened risk of inhaling the fine dust particles released during the operation. The composition of plastic eyeglass lenses can vary, but many formulations include polymers and additives. When milled, these particles become airborne and can become respiratory irritants. Prolonged exposure to these airborne particles may lead to respiratory issues, including coughing, wheezing, and in extreme cases, more severe respiratory conditions.
Moreover, certain plastic materials used in eyeglass lenses may contain hazardous substances such as bisphenol A (BPA) or phthalates. Inhaling dust containing these chemicals can have long-term health implications, including hormonal disruptions and potential carcinogenic effects. Protecting the respiratory health of workers is not only a moral imperative but also a legal obligation for employers.
Manufacturing Impact
Beyond the immediate health risks to workers, the release of these dusts into the environment can have broader consequences. Fine particles can settle on machinery and surfaces, and even contaminate adjacent work areas. This not only compromises the quality of the eyeglass lenses being produced but also poses challenges to maintaining a clean and efficient manufacturing environment.
The Role of Dust Collection in Eyeglass Lens Manufacturing
To mitigate the dangers associated with dust generated from plastic eyeglass lens manufacturing, implementing robust dust collection systems is paramount. Dust collection involves capturing and removing airborne particles at the source and preventing their dispersion into the air. This not only safeguards the health of workers but also contributes to maintaining a clean and organized workspace.
Apart from the health and environmental benefits, dust collection systems enhance the overall efficiency and precision of the milling process. Uncontrolled dust can interfere with machinery, leading to increased downtime and maintenance costs. By investing in effective dust collection, manufacturers can optimize production workflows, reduce downtime, and ensure consistent product quality.
Regulatory standards and workplace safety requirements further underscore the importance of dust collection in the milling of plastic eyeglass lenses. OSHA mandates the implementation of measures to control and mitigate occupational exposure to hazardous substances. Failure to comply with such regulations not only jeopardizes the well-being of workers. But it also exposes manufacturers to legal and financial repercussions.
In the pursuit of precision and clarity, it is imperative to acknowledge and address the hidden dangers associated with the dust generated in plastic eyeglass lens manufacturing. The health risks for workers, potential environmental impact, and the broader implications for manufacturing efficiency highlight the critical need for dust collection systems in this industry. By prioritizing the implementation of these systems, manufacturers can ensure a safer, healthier, and more efficient workplace, delivering high-quality eyeglass lenses while safeguarding the well-being of their workforce.
Welder’s anthrax, also known as metal fume fever, is a common occupational disease affecting welders and other metal workers. This condition is caused by inhaling fumes produced when welding certain metals, such as zinc, aluminum, and magnesium. The fumes produced by welding contain metal oxides that, when inhaled, can cause a variety of symptoms that can range from mild to severe.
Development and Symptoms of Welder’s Anthrax
Welder’s anthrax is a type of pneumonia and is caused by a bacteria that produces anthrax toxin. It is generally a short-term condition that usually develops within several hours after exposure to welding fumes. The most common symptoms of welder’s anthrax include flu-like symptoms, such as fever, headache, chills, nausea, and fatigue. In extreme cases, the symptoms can be more severe, such as chest pain, shortness of breath, and coughing.
When to Seek Medical Treatment
Though the symptoms of welder’s anthrax are similar to those of a common cold or flu, they typically appear more suddenly and can last for several days. In most cases, the symptoms will resolve on their own within a few days. However, in some cases, the symptoms can persist and may require medical attention.
Your doctor may perform a physical examination and take a blood sample to check for metal fumes in your bloodstream. In severe cases, you may be hospitalized and treated with medications to relieve your symptoms and prevent further exposure to welding fumes. If you suspect that you have welder’s anthrax, it is important to seek medical attention as soon as possible.
The Importance of Proper Ventilation
To prevent welder’s respiratory health hazards, it is important to have a comprehensive understanding of the sources of fumes and dust generated during the welding process. This can include the type of welding being done, the type of base and filler materials used, and the work environment. Based on this knowledge, appropriate dust collection systems can be designed to effectively collect the hazardous particulate.
Welder’s anthrax is not a long-term condition, but it can cause discomfort and can impact your ability to work. If you employ welders, it is important to take steps to prevent welder’s anthrax. Speaking to professionals to help determine the best solution for your facility is a good first step.
Partner with Imperial Systems to Help Prevent Welder’s Anthrax
Imperial Systems can partner with you to design a system tailored to your system and facility. We assess your work environment and design a system that integrates with your workflow while ensuring that employees are staying healthy.
Welder’s anthrax is a common condition that affects welders and other metal workers. Inhaling welding fumes can cause a range of symptoms, from flu-like chills to more severe issues in serious cases. The best way to prevent welder’s anthrax is to ensure any areas where welding takes place are properly vented with a fume extractor.
Plasma cutting is a powerful tool for metal fabrication, but it also creates a significant challenge – dust. Above all, fine metal particles and harmful fumes can pose serious health risks to workers. They also contaminate the shop environment and even damage equipment. But fortunately, plasma cutting with zoned downdraft tables offers a strategic solution for effective dust control.
The Zoned Advantage: Targeted Capture for Airflow Efficiency
Unlike traditional flat-surface tables, zoned downdraft tables partition the cutting surface into individual sections, each equipped with its own damper to allow or restrict airflow. As a result, this targeted approach provides several key benefits:
Reduced Airflow Requirements: Zoned tables require significantly less airflow compared to single-chamber designs. This is because only the active zone where cutting is occurring needs airflow, significantly reducing energy consumption, noise levels, and the size and cost of the required dust collector.
Enhanced Dust Capture Efficiency: By focusing airflow on the active zone, dust and fumes have less opportunity to escape. This targeted capture approach improves air quality, protects worker health, and minimizes environmental pollution.
Flexibility for Different Workpieces: Zoned tables can accommodate different-sized workpieces by activating only the zones covered by the workpiece. This eliminates unnecessary airflow over empty areas, further optimizing energy consumption and noise reduction.
Design Options in Zoned Downdraft Tables for Diverse Needs
Zoned downdraft tables are available in various configurations to cater to different workshop needs and workpiece sizes:
Grid Zoning: Ideal for smaller tables, this layout divides the surface into evenly sized squares, each with its own duct connection.
Sectional Zoning: This is perhaps the most common layout, and dampers can be adjusted based on where the cutting head is working. This maximizes surface coverage and minimizes airflow needs.
Custom Zoning: For complex shapes or specific cutting patterns, custom zone layouts offer ultimate flexibility, ensuring optimal dust capture for any project.
Optimizing Dust Collection for Maximum Performance
Effective dust control in zoned downdraft tables goes beyond simply dividing the surface. Several key elements work in concert to ensure optimal performance:
Ductwork Design: Properly sized and strategically positioned ducts are crucial for ensuring smooth airflow and efficient capture. Further, duct diameter, bends, and connections must be carefully considered for optimal performance.
Damper Systems: Automated dampers can open and close individual zones, further reducing unnecessary airflow and optimizing energy consumption. Depending on the size of the cutting head, multiple zones may be open at a time.
Airflow Velocity: Maintaining the correct airflow velocity within each zone is essential for efficient capture without excessive energy usage. So, balancing airflow velocity and energy efficiency is key.
Investing in a Cleaner and Safer Future
While zoned downdraft tables may require a higher initial investment compared to traditional flat-surface tables, the long-term benefits are significant. Reduced energy consumption, smaller dust collectors, improved worker health and safety, and a cleaner work environment all contribute to a positive return on investment. For shops prioritizing efficiency, safety, and environmental responsibility, zoned plasma cutting tables offer a strategic and sustainable solution to dust control challenges.
As the demand for minerals and other resources continues to rise, so does the need for more mining. It has become crucial to prioritize the implementation of proper safety measures to protect both the environment and miners. One key aspect of ensuring operational safety in mining processes is effective dust collection. The generation of hazardous dust in mining, such as silica, coal, and asbestos, poses significant health risks to workers and can contribute to environmental pollution.
By implementing effectively designed dust collection systems, mining companies can minimize the release of harmful particulates into the air, protecting miners’ respiratory health and reducing the potential for long-term occupational diseases. Prioritizing dust collection in mining operations ensures the well-being of workers and the preservation of the environment, leading to sustainable and responsible mining practices.
Mining Processes and Dust Challenges
Various processes such as drilling, blasting, crushing, and grinding produce a substantial amount of mining dust. Let’s discuss the different types of mining and the specific dust collection challenges they pose.
Underground Mining
This involves extracting minerals and ores from beneath the earth’s surface, which poses unique challenges for dust collection. Dust is generated during drilling, blasting, and cutting of rocks and coal, which can cause respiratory issues for miners. Additionally, the confined spaces of underground mines can make it challenging to manage and maintain dust collection systems. It is essential to have specialized equipment that can effectively capture and control the specific dust being generated, such as a heavy-duty dust collector.
Surface Mining
The surface mining process involves extracting minerals and ores from the surface of the earth, also generates a significant amount of dust. Dust is produced during the excavation, crushing, and transporting of materials, which can cause respiratory issues and eye irritation for workers. In addition, surface mining can have a significant impact on the environment, with dust and other pollutants affecting nearby ecosystems. Proper dust collection systems can help mitigate the impact of surface mining on both workers and the environment.
Open-pit Mining
This is removing minerals and ores from an open pit or borrow. The excavation and transportation of materials can create significant amounts of airborne dust, which can affect not just the health of workers, but also the health of local community members. Like surface mining, open-pit mining can have adverse effects on nearby ecosystems. Effectively designed dust collection systems will keep the environmental impact of hazardous dusts to a minimum and keep employees and residents safe and healthy.
The CMAXX Dust & Fume Collector: Built for Mining’s Tough Demands
Because of the hazardous nature of dusts produced from mining, a heavy duty dust collector is essential. Our CMAXX Dust Collector includes as standard, 7 ga. and 10 ga. steel construction, abrasion-resistant inlets complete with UHMW lining, baked-on powder coat inside and out, and many more features to address the harsh mining environment. DeltaMAXX Prime cartridge filters are able to remove silica, coal, asbestos, lead, mercury, and other dusts from the air meeting the strictest environmental regulations for permitting.
Dust collection is crucial in the mining industry to protect workers’ health and safety and minimize the impact on the environment. With specialized equipment and systems designed to capture and control dust effectively, mining operations can operate safely and sustainably. Contact Imperial Systems to discuss your mining dust collection solution today.
This is the last Dusty Jobs Podcast episode from Fabtech 2023. In this episode we talk with Luke Surratt from Mazak Optonics Corp. Luke talks about some the new laser cutting technology Mazak has to offer as well as new automation. He also talks about their service and installation offerings.
Narrator: Welcome to the Dusty Jobs podcast from Imperial Systems. Industry knowledge to make your job easier and safer.
Donovan: Hello and welcome to another episode of the Dusty Jobs podcast. We’re still at Fabtech, day four. Joining us now is Luke Sarat from Mazak. How you doing Luke?
Luke: Good. How about you?
Donovan: Well I am – I’m glad to be sitting down. It’s been a long show. How about you?
Luke: Yeah, same. Ready to go home.
Donovan: Exactly, yeah, yeah. So we’re finally wrapping it up here. Do you guys have a good show so far?
Luke: Excellent show. One of the best in in my tenure here at Mazak. You know a lot of good boot traffic, a lot of good leads, a lot of new stuff, a lot of exciting things to see.
Donovan: Yeah, yeah, and we’ll get into it in a minute why a lot of people came into your booth. How did you get into this industry? Today we kind of have a lot of students walking around and what’s your role over at Mazak? What do you do there?
Luke: So I’m general manager of customer service. Been at Mazak Optonics almost 22 years. Started out of college as a field service engineer. Did multiple jobs throughout our service group.
Donovan: So field service engineer. What’s that?
Luke: So traveling, installing, servicing our equipment Monday through Friday. Seeing the country on Mazak.
Donovan: Yeah there you go. There you go. So some of these young people that might be a career they would be interested in something like that. So yeah sorry keep going.
Luke: Yeah so did that for about 10 years or so. Then ended up having a family. So moved more into an in-house role. Service supervisor, was training supervisor. I ran our installation group for about eight years. So I was installation manager and then moved to general manager of customer service. So service, support, basically anything customer facing is underneath me.
Donovan: Well that’s incredible. That’s great because that just shows that one, if you’ve been with a company that long – great company.
Luke: Yep.
Donovan: Two, that they promote from within and guys like you who are now in upper management, you got there because you know what’s going on below. You know everything your guys are going through you’ve gone through it yourself and that’s just great when you can see that in a company that you know you can really relate to the guy who’s out there traveling. You’ve done it.
Luke: Too well sometimes. But yeah I mean it’s it’s been a great company. It’s been a great ride. You know one thing that’s kept me there is our technology. Constantly advancing. Constantly changing. There’s always something new, always something you can learn.
Donovan: So well well let’s get to that something new. That’s why you probably got a lot of people in your booth. You guys had something to come out this year, right?
Luke: Yeah. So we showed a couple new things this year at the show. First – sorting robot. So it’s a pick and place robot. We have it on the… we have a seven kilowatt Neo.
Donovan: Pick and place?
Luke: Yeah. So we got a seven kilowatt Neo. Seven kilowatt fiber laser with a KST automation which is your raw material and your skeletons end up right above the two PC. Small footprint and then it comes out to a third position with an actual robotic arm that is taking the parts out of the skeleton and placing them on pallets.
Donovan: Okay so unlike some other tables, table’s gonna you’re gonna have a piece of metal out and then it’s gonna slide in – it’s gonna get cut. And then and then it’s gonna slide back out. And then once it gets back out of the unit there’s gonna – you guys have a robot now that pulls all those parts off.
Luke: Yeah so it actually comes out your standard laser has two pallet changers. So it comes out to your cutting position and then like a loading and unloading style position. So it comes out to a second position and you could put the whole nest back up in the tower. Traditional kind of loading and unloading of a laser. Or it can come out to a third position where the robot is and actually pick the parts out of the sheet. Once it’s done picking the parts it’ll go back into that second position and unload the skeleton into the automation.
Donovan: Oh, so does it know from the program how to organize those parts also?
Luke: Yes. Yes all out of the programming software. So the same software that’s driving the laser, the NC code, to cut the parts is driving the sorting program.
Donovan: So I could have possibly three or four different pieces on one cut and the robot will know how to sort them and put them in the appropriate piles or places.
Luke: Correct.
Donovan: Wow that’s got to save some time there.
Luke: Yeah. Yeah I mean that’s you know in this industry everybody’s hurting for one thing right now and it’s people. Skilled people. You know most shops you go to have two or three people with a lot of lasers that are shaking and sorting parts all day long and this is just a solution for our customers to eliminate the manpower of sorting parts.
Donovan: Right. Right. And then it’s it’s uh it’s gonna keep things safer a little bit too, right? Oh you know not not as much handling not as much attention for people cutting or dropping something on themselves.
Luke: Yeah I mean it it’s not gonna call in sick it’s gonna show up. Yeah it’s gonna work. Nights and weekends.
Donovan: Yeah. Well the shop can that work lights out.
Luke: Yes it can.
Donovan: So you could you get at the end of the day you could load that up and then come back in the morning and all your parts are sorted there.
Luke: Yep. Ready to go for next process in the next morning.
Donovan: So we were talking to a couple other people earlier in the day about plasma tables. And when we talk about a laser table, how hard is it for someone to learn how to use that table? Is it is it pretty easy? I mean if there’s someone out there that one of these young people and they’re listening they’re going oh I never thought I could have a job as a laser table operator. I mean is that something that would require a college degree?
Luke: Most, no. No, it would not require a college degree even to come you know start out with us you know we promote a lot like you were talking earlier from within. You know a lot of younger generation you know know what they’re doing, got a good head on their shoulders. They’ll come into Mazak and we’ll start them on a path to become a field service tech. We do a lot of training and growing from within, as well as going into the workforce. There’s really not a big difference from operating a plasma table to a laser. It’s a different technology. The M and G code, the programming, most of it’s all the same.
Donovan: So but it’s not it’s not overly complicated is what I mean. Do you think I could do it?
Luke: Yeah.
Donovan: Well if I could do it probably a lot of people out there could do it. So, well that’s great because that’s just another opportunity for you know young people coming out of high school, coming out of trade schools that they could learn this job, learn this field. And I mean you guys are selling a lot of these things, right?
Luke: Oh yeah.
Donovan: So there’s gonna be a need for people to be out there and running them.
Luke: There’s a need for running them. There’s a need for people to service them. There’s need all the way around. You know, manufacturing has kind of gotten a bad wrap in the industry, you know of you go in to your guidance counselor showing you a Ford Model T plant. But that’s not manufacturing these days. You know shops are clean, very environmentally friendly and safe, and you know most shops we go into now painted floors very nice facilities, you know. It’s not the manufacturing what people think about there’s a ton of technology in manufacturing. You know many of the shops got a AGV’s running around moving the material from place to place, things that you wouldn’t even think about.
Donovan: Well and I don’t I don’t think we’re ever gonna go backwards either. Everything is just gonna keep getting more advanced. And I’d say if you’re a young person coming out of school right now it’d be a great field to start looking into.
Luke: Oh yes, for sure.
Donovan: Because you can learn it now and keep going because like you said things just keep getting better. You guys just came out with the sorting robot that wasn’t even a thing six years ago that people were thinking about. And you guys – did you guys come out with a new laser this year?
Luke: Yes we did. We also debuted here at Fabtech our larger platform laser. It’s a 4.2 meter bed by 2 meter bed so 4.2 by 2 larger platform.
Donovan: That’s big.
Luke: Yes it is. And 20 kilowatt. So up until this week you know the highest laser power Mazak was doing was 15 kilowatt. So now we’re up to 20 kilowatt.
Donovan: So what’s that additional kilowattage? What’s that allow you to do?
Luke: So it allows us to do more capacity – thicker material, you know, that two inch aluminum or that two inch stainless but that’s not really the core of the market for that machine. The core is to be able to take your mid-range material so I’d say 3/8’s up to 3/4 and cut it faster. You know 10 years ago if we were sitting here everyone was cutting with oxygen to help accelerate the process to help the melding process of the material. That’s what you need to use on a lower powered laser to cut thicker material. Now in that leaves an oxide edge on the side of the part. So everyone would have the second process in it for paint or powder coat. You know get that oxide off the edge. Where cutting it with nitrogen or shop air for an assist gas. You don’t have the oxidation. So now as the power increases the capacity to nitrogen or oxygen cut increases and it’s much faster.
Donovan: That makes a lot of sense. So you can cut faster and cleaner.
Luke: Yes.
Donovan: So if you bought a new laser from you guys with the robot basically you could go right out of that process into powder coating if you needed.
Donovan: So you can almost eliminate with your guys new system you can eliminate three steps in the process. Of what it takes to get things done.
Luke: Yeah. Or not have to invest much in your powder or your paint system. You know it not always was a secondary process to get the oxide off. A lot of places would put extra steps in the wash cycle for their paint system. Which costs money and time as well.
Donovan: Right. Right. Yeah. And everybody’s trying to be more efficient. Nobody wants things to take longer. Well that’s that’s exciting stuff. That’s exciting stuff. So just trying to think through anything else that you guys might… you guys do all your own service work like we were talking about earlier. Yep. Guys are install service full turnkey.
Luke: Yeah. Full service. You know Mazak we’ve had lasers in the US since 1986 and we still service and support everything back to 1986. Full part stock service. Capacity people.
Donovan: Oh wow. That’s impressive.
Luke: Yeah. So you know you buy something from Mazak you know a lot of the competitors other industries will throw you to a third party after seven to ten years. Not us. We are a hundred percent will work on everything we’ve ever sold.
Donovan: Well that’s great. That’s great. Well hey I know it’s been a long week.
Luke: Yes it has.
Donovan: We’ve all had a long week and I appreciate you just giving us a couple minutes to come talk.
Luke: I appreciate you guys taking the time.
Donovan: Yeah. Yeah. And so is there anything else you want to share about if anybody’s trying to get a hold of Mazak, if they’re interested in a laser. What’s the best way to do that? What’s the best way to look you guys up?
Luke: The best best way generally is to jump on our website. You know MazakOptonics.com. Can connect with us there.
Donovan: And you guys have a showroom locally, too, correct?
Luke: Correct. We have a showroom. It’s in Elgin, Illinois which is about 30 miles here from downtown Chicago.
Donovan: Yeah. So if someone wanted to come out and actually see one working in person, and they didn’t make it to Fabtech they could come out and see you guys.
Luke: Yes they can.
Donovan: So that’s great. Well Luke, thank you so much for coming on. Go check out Mazak on their website. I bet you guys got some stuff on YouTube and other things too.
Luke: Yes we do.
Donovan: They’re on LinkedIn and you can find us on all those platforms too. Facebook, LinkedIn, YouTube, TikTok. We’re on them all. So feel free to check us out on those and until we talk to you next time stay healthy stay safe.
Luke: Okay. Thank you.
Narrator: Thanks for listening to the Dusty Jobs podcast. Breathe better, work safer.
Manufacturing Impact
