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Does Your Welding Fume Extractor REALLY Suck

When you invest in a welding fume extractor, you expect it to remove fumes from the workplace, for a safer, compliant, and more pleasant environment. But will you - or did you - get what you paid for?

A fume extractor - whether that's a mobile extractor, downdraft table, or torch extractor - seems like a pretty basic device; a box that contains a fan and a filter. However, in reality there's a lot of variation in design from one brand/model to another, and this can have a big impact on how well the extractor does (or doesn't do) it's job.

The Vacuum Cleaner Analogy

After investing in a fume extractor - whether by spending your hard-earned money or persuading your employer to fund it - the last thing you want is to discover is that it doesn’t effectively remove fumes. Sadly, this can and does happen. With many brands and models on the market, not all are built to the same standard.

Think of it like a vacuum cleaner with weak suction. It might have seemed like a bargain at first, but when it struggles to do the job, it quickly becomes a frustrating waste of money. Now, compare that to a high-powered vacuum that makes cleaning effortless. No contest!

The same applies to welding fume extractors. If you or your team are constantly battling with an underperforming unit, you’ll eventually need or want to replace it—wasting both time and money. 

In this article, we share some points to be aware of when looking for your next fume extractor, so you can be confident that it really does suck!

Compare The Airflow Rating

The airflow rating - typically shown in m³ per hour, or m³/hr - is one indication of how well a fume extractor will perform. Most manufacturers will provide a 'maximum' airflow rating.  This will allow you to compare airflow rating makes and models, however you should also be aware that: 

• Maximum airflow rating is measured with a new filter that has had no use, so does not give indication of how well the unit will perform under load (when the filter starts to fill with fume dust)
• This rating is often a very imprecise measurement and determined under very favourable conditions that don't reflect 'real life' use - such as with the suction arm removed or completely straight 

What Influences Suction Performance?

Manufacturing a welding fume extractor that has both a) effective filtration and b) good suction power is more challenging that what it appears. Improving one of these factors can often have a negative impact on the other, requiring the careful application of science (aerodynamics and aeroacoustics) and experience to achieve the best overall design. 

Here are the main factors the influence how an extractor will perform:

1. Extractor Internal and External Design

At glance, a fume extractor seems like fairly basic technology; a box that contains a fan and a filter. The science of aerodynamics, however, is more complex than it looks.  From the outside, different makes and models may appear to be more or less identical, but inside the unit there are often subtle differences in design that significantly affect aerodynamic efficiency and suction power.

Aerodynamics: Differences in internal design - especially 'upstream' of the fan, from the fume extraction point, through the filter, to the fan - will impact air volume and how smooth or turbulent the airflow is. 

Leakage: No fume extractor is ever 100% airtight and will always have an element of leakage (where air is drawn into the unit from points other than the main/intended suction point). The higher the leakage, the less efficient the unit will be, and the less suction power it will have.

Size: Most operators will obviously prefer units that are smaller and save take up less space/footprint. However, reducing the size of an extractor can reduce airflow volume. Smaller is not always better!

Fan and Motors: Differences in the size and shape of the fan impellor, and type of motors used will also impact on suction power.

2. Filter Design and Size

Standard vs HEPA Filters: Many fume extractors are offered with "high efficiency" filters, such as HEPA (or H13 grade), that offer higher levels of filtration (filters out smaller particles) compared to "standard" filters such as F9 grade.  While this may sound like a very obvious advantage, you should also be aware that one disadvantage is that a higher grade filter will reduce airflow and suction power. Higher grade filters will also collect more fume/dust, which in turn further reduces airflow as the filter becomes full.

As a result, high-efficiency / HEPA filters may not always provide an overall improvement in all applications. While the filtered air will be 'cleaner' than standard filters, the overall volume of filtered air may be lower - resulting in higher fume concentration in the work environment.

Filter Size: Filters with a larger surface area will obviously allow for higher airflow / volume. This should always be considered alongside the type of filter system. Some filters have a larger surface area, but will clog faster, resulting in loss of suction power. See more details on this topic here.

4. Manufacturer Expertise and Experience

Choosing an experienced manufacturer of welding fume extractors offers clear advantages in performance, reliability, and long-term value. With a proven track record, experienced manufacturers have refined their designs over time, drawing on real-world feedback to create systems that are more effective at capturing and filtering hazardous fumes. Their products are typically built to higher quality standards, ensuring consistent performance and durability in demanding industrial environments.

In addition, established manufacturers often provide better support, spare parts availability, and compliance with safety regulations — giving you greater peace of mind and reducing the risk of costly downtime or replacements.

The ALLCLEAR Advantage

ALLCLEAR^® by Weldclass is market-leading brand that has delivered welding-specific fume control solutions to Aussie welders and metal fabricators for over 15 years. 

With ALLCLEAR, you get what you pay for: powerful fume extraction, reliability, and features that make a difference.

Get a Quote | Request a Demo    View The ALLCLEAR Range

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