Extracting Soldering and Welding Fumes – Capturing Emissions Directly at the Source
Effectively Extract Soldering and Welding Fumes—Tailored to the Process, Material, and Worksite
Welding and soldering produce various mixtures of hazardous substances. Welding fumes consist primarily of very fine particulate matter; depending on the process, base and filler materials, coatings, and process parameters, gaseous hazardous substances may also be present. Soldering fumes contain, among other things, particles and decomposition products of the flux. Their composition and associated hazards must therefore be assessed on a case-by-case basis.
EVOTEC tailors the intake, airflow rate or negative pressure, filter stages, air recirculation, and exhaust to the actual workplace—either as a mobile solution for changing locations or as a stationary solution for permanently connected processes and multiple intake points.
Your benefits with soldering and welding fume extraction:
Measuring Emissions Directly at the Source
Burner-integrated extraction systems, extraction arms, flanges, tables, or hoods capture smoke and fumes as close as possible to where they are generated.
Adapt the filtration concept to the process
Particulate filters, sorption stages for gaseous components (if applicable), and W3 requirements are selected based on the specific hazard.
Mobile and stationary solutions
Mobile devices support flexible workstations; stationary systems support continuously connected processes and multiple data collection points.
What emissions are generated during your soldering or welding process—and where can they be most effectively captured? Please provide us with details on the processes, materials, filler materials, fluxes, and operating procedures. We will work with you to review the data collection and filtering approach.
What happens during welding and soldering?
Welding fumes and soldering fumes are not uniform substances. The key factors are the process, temperature, workpiece, filler material, flux, coatings, and contaminants. The risk assessment must therefore take into account both particulate and gaseous components.
Welding fumes: fine particles and process gases
Welding operations generate very fine particulate hazardous substances. Depending on the process and material, these may include, for example, metal oxides as well as gaseous substances such as ozone or nitrous gases. The composition is largely determined by the base and filler materials, coatings, and process parameters.
Solder Fumes: Flux Products, Particles, and Vapors
During soft or hard soldering, metal-containing particles and decomposition products from fluxes may be produced. Rosin, amines, and other reaction products can irritate the respiratory tract and eyes. Therefore, it is not enough to assess only visible fume; gaseous components and the specific brazing chemistry must also be taken into account.
Technical Note: BG ETEM on solder fume emissions during soft soldering.
Appearance and odor are not reliable indicators of hazard. Protective measures must be tailored to the substance data, the process, the duration of exposure, and the actual exposure conditions.
Why is collection at the source so important?
The closer the extraction system is to the source of the fume, the less fume enters the breathing zone and the air in the hall. The measurement must account for thermal buoyancy and process movement without disrupting the inert gas flow or the process.
Detection near the source before it spreads
Burner-integrated extraction systems, extraction flanges, adjustable extraction arms, extraction tables, or enclosures capture emissions directly at the process. The appropriate option depends on the component, the seam path, the range of motion, and the required air flow rate or negative pressure.
Room ventilation is a supplement
Mechanical ventilation can capture residual emissions and protect third parties, but it does not replace effective capture at the source. TRGS 528 generally requires local exhaust ventilation at the source during manual welding; additional general ventilation is designed according to the specific conditions.
How are soldering and welding fumes captured?
An effective system combines proper collection with proper separation. Particles, gaseous components, sparks, filter loading, and planned air recirculation must be considered together.
Sensing Element and Operating Point
The extraction arm, burner exhaust, hood, or table must be aligned with the direction in which the fume spreads. Key factors include the capture distance, tracking, air flow rate, negative pressure, and disruptive cross-drafts. An improperly positioned capture system may remain ineffective despite high system performance.
Particle Filtration and W3
Welding fume particles are captured in appropriate filter stages. When recirculating purified air and carcinogenic welding fume components, the specific requirements must be observed. Equipment tested in accordance with DIN EN ISO 21904-1 and -2 may be labeled as W3 and approved for the corresponding air recirculation.
Technical Note: IFA/DGUV on the Testing and Certification of Welding Fume Extraction Systems.
Gaseous Components in Soldering
Particle filters alone do not reliably remove gaseous decomposition products. If such substances are a concern, an application-specific sorption stage—often using activated carbon—is added. Sorption media have a limited adsorption capacity and must be monitored and replaced as appropriate for the mixture of substances.
Sparks, Filter Maintenance, and Safe Disposal
During welding processes, sparks and hot particles can enter the extraction system. Pre-filtration, spark traps, appropriate filter media, and safe discharge and replacement procedures reduce the risk of fire and exposure. Maintenance and filter replacement should be part of a defined safety plan.
Filter class or nominal airflow alone do not guarantee a safe solution. It is the combination of air intake, airflow, filtration, monitoring, maintenance, and the intended air recirculation that determines the system’s effectiveness.
Mobile and stationary extraction systems
Mobile Devices for Flexible Workplaces
Mobile extraction and suction units are suitable for changing workstations, rework, maintenance, and tasks confined to a specific area. The collection element, filter configuration, and suitability for continuous operation must be appropriate for the specific soldering or welding process.
Stationary systems for multiple data collection points
Stationary systems supply permanently connected extraction arms, machines, tables, hoods, or robotic welding cells. The ductwork, simultaneous-use factor, pressure drop, filter cleaning, and discharge are designed for the actual operating point.
High vacuum and burner-integrated detection
Systems with integrated burners capture welding fumes very close to the source and typically operate with low flow rates and higher negative pressure. The design must ensure that the fume plume is captured without interfering with the shielding gas process.
Low vacuum with arm, hood, or table
Exhaust arms, hoods, and tables operate with larger air volumes and capture emissions over a larger area. Capture distance and tracking remain critical; in automated processes, enclosures and tracked capture are often particularly effective.
Typical extraction solutions: burner-integrated · extraction arm or flange · extraction table · hood or enclosure.
What does the interpretation depend on?
A robust design starts with the actual process. The material, additives, flux, emission rate, workstation geometry, operating time, and air recirculation determine the technical solution—not just the visible amount of smoke.
Processes, Materials, and Additives
Welding processes, current, wire or electrode, base material, coating, and surface contaminants all influence the type and amount of emissions. In soldering, the solder alloy, flux, temperature, and number of workstations are additional factors.
Measurement, Operation, and Air Recirculation
The following factors must be clarified: type of monitoring, required airflow, pressure drop, simultaneous operation, shift work, filter service life, maintenance, discharge, and exhaust or recirculation mode. For carcinogenic substances, additional requirements apply to air recirculation.
Effectiveness must be verified during commissioning and during operation. For welding fume extraction systems, the DGUV recommends checking the extraction flow rates during commissioning and at regular intervals, at least once a year.
Which extraction system is right for your workplace?
Please provide us with details regarding soldering or welding processes, materials, filler materials, workstation geometry, operating time, and desired air recirculation. EVOTEC will assist you in selecting a suitable mobile or stationary solution.
Correctly Classify W3 Labeling and Air Recirculation
W3 refers to a tested welding fume filtration class for appropriately certified equipment. It is particularly relevant when purified air containing welding fumes with carcinogenic components is to be recirculated into the work area. However, a W3 designation does not replace the risk assessment or the proper selection, installation, maintenance, and performance monitoring of the equipment. For soldering fumes and their gaseous components, the filtration system must be evaluated separately.
Mobile Devices for Various Soldering and Welding Tasks
Mobile units are suitable for changing workstations, localized tasks, and cleaning in environments involving soldering and welding processes. The product shown here, which is specific to this application, is a preliminary selection. The sensing element, airflow capacity, filter stages, suitability for continuous operation, and permissible air recirculation must be appropriate for the specific process.
EP 1702/ 1703
High-performance industrial dust collector with very high airflow and a large filter area for capturing large quantities of dust and particles; also available in an EX version.
Stationary extraction systems for soldering and welding fumes
Stationary systems are suitable for permanently connected extraction arms, welding tables, enclosures, robotic cells, and multiple extraction points. The tagged series shown here are a preliminary selection. The ductwork, operating point, filter and discharge systems, and safety features are designed to meet the requirements of the actual process.
FEX 1000.1: Welding fume, soldering fume and dust extraction
- Powerful EC blower suitable for continuous operation (24/7), large air volume, infinitely variable volume flow control
- Due to low construction height also usable as an under-table unit
- Modern control technology with display of device status and filter messages
- Reliable filtration through multi-stage combined filter system
- Connection for on/off remote control
FEX 3000 VA welding fume, soldering fume and dust extraction system
- Powerful EC blower, suitable for continuous operation,
- Large air volume, infinitely variable volume flow control
- Modern control technology with display of appliance status and error messages, connection for on/off remote control
- Reliable filtration thanks to graduated combination filter system
- available in the "EX" or"W3" versions
FEX 3000.1/ .2: Welding fume, soldering fume and dust extraction
- Powerful EC blower suitable for continuous operation (24/7), large air volume, infinitely variable volume flow control
- Modern control technology with display of device status and filter messages
- Reliable filtration through multi-stage combined filter system
- Connection for on/off remote control
- FEX 3000.2 with silencer and air outlet diffuser for extra low sound pressure level
FEX 4000 fume and dust extraction system
- Mobile, robust system with ESD powder coating
- Reliable filtration thanks to multi-stage filter system with pneumatic cleaning (compressed air required)
- EC blower suitable for continuous operation (24/7) with infinitely variable volume flow control
- Modern control technology with display of appliance status and error messages, optional connection for on/off remote control
FEX 5000 PRO: Welding fume, soldering fume and dust extraction
- Powerful EC or medium-pressure blowers, suitable for continuous operation (24/7), large air volume
- Modern control technology with display of device status and filter messages (PRO.1/ .2)
- High air volume and large filter surface
- Silencer and outlet diffuser for extra low sound pressure level
EP 2701-02-03 Industrial dust extractor
- Robust equipment with V2A stainless steel (1.4301)
- Powerful EC suction motors, suitable for continuous operation
- Automatic pneumatic filter cleaningvia PLC control
- Optional: ESD version or EX protection ATEX Zone 22
EP 2815/ 2822 Industrial extraction system
- For extracting free-flowing, dry dusts, as well as suspended dusts and fumes during Welding, grinding, polishing
- Powerful medium-pressure turbine suitable for continuous operation (24/7)
- Large air volume, frequency converter (FC) for volume flow control
- Large filter cartridges with automatic compressed air cleaning for long filter service life
- PreCoat as a filter aid (optional) for complicated dusts
EP 2830/ 2855/ 2875 Industrial extraction system
- Very strong suction power, suitable for pipe systems, with various openings for connection
- Frequency inverter for automatic volume flow control, fully equipped with safety features
- Remote on/off possible with practical handheld
- Monitoring of dirt container fill level, including convenient lowering for disposal
EP 28110 Industrial extraction system
- Very strong suction power, suitable for pipe systems, with various openings for connection
- Frequency inverter for automatic volume flow control, fully equipped with safety features
- Monitoring of dirt container fill level, including convenient lowering for disposal
Frequently Asked Questions About Soldering and Welding Fume Extraction (FAQ)
What is the difference between soldering fumes and welding fumes?
Welding fumes consist primarily of very fine particles and, depending on the process and material, may contain additional gaseous hazardous substances. Soldering fumes contain particles and decomposition products from solder and flux. For this reason, the collection and filtration stages for both processes are evaluated separately.
Where is the best place to detect fume?
As close as possible to the source of the fumes and in such a way that thermal convection is utilized. Depending on the application, options include burner-integrated extraction, an extraction arm, a flange, a table, a hood, or an enclosure. Cross-drafts and excessive distance can significantly impair extraction.
When is a W3-certified device relevant?
W3 is particularly relevant when welding fumes containing carcinogenic components need to be captured and the purified air recirculated back into the work area. The key factors are the risk assessment, current regulations, and the certification of the entire unit—not just a single filter element.
When is a mobile solution appropriate, and when is a stationary solution appropriate?
Mobile units are suitable for changing work locations and tasks confined to a specific area. Stationary systems are designed for permanently connected processes, multiple collection points, and continuous operation. Airflow, negative pressure, the simultaneous operation factor, and the filtration concept determine the selection.
How often should the filters and the suction performance be checked?
Replacement intervals depend on emissions, operating time, filter loading, and the manufacturer’s specifications. The exhaust airflow rates must be checked during commissioning and at regular intervals; the DGUV requires at least one annual inspection for welding fume extraction systems. In addition, differential pressure, detection, and safe filter replacement must be monitored.
Your partner for industrial extraction solutions
EVOTEC develops mobile and stationary extraction solutions for industrial soldering and welding processes and produces not only production-ready equipment but also application-specific custom solutions. Our systems are designed for effective extraction, process reliability, durability, and specific operating conditions.
Commissioning
Maintenance
Which soldering or welding fume extraction system is right for your process?
Please provide us with information on the processes, materials, filler materials or fluxes, the collection point, operating time, number of workstations, and planned air recirculation. EVOTEC will assist you in selecting a suitable mobile or stationary solution.
Robin Buschbaum
Sales D/A/CH
Specialist for extraction technology
vertrieb@evo-products.de
02642 9373-53
Lars Blankenburg
Sales
lars.blankenburg@evo-products.de
02642 9373-10
Asim Zaman-Pahlke
Export Sales
export@evo-products.de
02642/9373-15