Air Pollution Control Equipment
for heavy manufacturing
What we did:
Pure Skies pollution control equipment reduced PM2.5 and PM10 about 80% and 90%, respectively, at a heavy manufacturing plant.
One of Devic Earth’s customers is an MNC which manufactures earth moving equipment. The customer was particularly concerned about the health effects of air quality inside one of their plants in the Delhi-NCR area, covering approximately 18,000 sq.
Levels of air pollutants inside the plant were at hazardous levels before Pure Skies was installed.
Baseline air quality was measured over a one-week period before a Pure Skies air purifier was installed. Levels of particulate pollutants – PM2.5 & PM10 – inside the plant werehazardous:441 ± 21 µg/m3&494 ± 24 µg/m3,respectively. These exceed both National Ambient Air Quality Standards, and are about 20 times higher than the standards of the World Health Organization.
Processes such as welding, metal cutting, and metal buffing lead to high levels of particulate pollution inside the plant.
Other sources of pollution include neighboring factories in the industrial zone in which they are located, as well as vehicle emissions from the adjacent highway.
Portable fume extractors and an extensive network of exhaust fans and ducting were in place, but there was minimal benefit.
Figure 1: Pure Skies base station installed on a pedestal inside the plant floor. An air quality monitor was installed about 50 m away from the base station. An additional Pure Skies extender unit (not shown) was placed just outside the main shutters to the plant.
Installation took a few hours. Equipment was installed on support columns or beams. No floor space was required.
Due to high ambient pollution levels in Delhi-NCR, and especially in the industrial zone, air pollution levels outside the plant were also exceedingly high. Ambient PM levels recorded by the CPCB reference air quality station just a few km away would frequently cross 300 mcg/m3 during the smog season. That’s like breathing a dozen cigarettes at once!
To compensate for high air pollution levels outside the plant, Devic Earth technicians installed an additional Pure Skies extender unit just outside the plant shutters to minimize the entry of polluted air into the plant premises.
Within 4-weeks of installing the Pure Skies unit in the plant, the 24-hour average PM2.5 and PM10 levels were reduced by 28% and 29%, respectively.
The smart technology in Pure Skies then took over. The system integrates numerous data points:
Plant data (number of workers, amount and type of weld wire used)
Air quality data from the third-party monitor
Local meteorological data (precipitation, wind direction and wind speed, humidity, and temperature)
Air pollution data from the nearest reference air quality station
The Pure Skies smart technology continuously learns from local conditions and optimizes the output of each Pure Skies base station and extender accordingly.
Over the next 5 months, levels of particulate pollutants – PM10 and PM2.5 – were reduced by 80-90% with Pure Skies, as compared to baseline!
Plant output and employee head count were steady during this period. These benefits in air quality have been sustained over the past one year.
Figure 2: Average pollutant levels and % reduction at the earth moving equipment manufacturing plant. The red and green bars are the Pure Skies-Off(1-month) and Pure Skies-On periods (1-month), respectively. The successive green bars depict the incremental decrease in the levels of the pollutants over 1-month intervals. Data source: 3rd party air quality monitor (Airveda Pvt. Ltd., Gurgaon), pre-calibrated against a reference grade monitor.
Unlike air purifiers which use HEPA filters or ESPs, Pure Skies air purifiers use pulsed radio technology in the Wi-Fi spectrum to cover large areas effectively and maintain low levels of particulate pollutants over time. This makes Pure Skies an excellent choice for improving air quality over large indoor spaces.
What’s the value of cleaner air to you and your plant?
Reduced sick days
Cleaner air means a stronger immune system. A study from several of Devic Earth’s customers showed sick days reduce by 11-13% year-on-year after installing Pure Skies!
Worker productivity drops by 1% for every increase in PM2.5 levels by 10 mcg/m3, according to researchers from Columbia University. For a typical factory with PM2.5 levels averaging 80-90 mcg/m3, that’s like watching productivity drop by 4-5%!
Improving air quality index (AQI) to less than 50 improves the productivity of employees by 5-6%, which in turn increases the profitability of the company by 1%, according to a study published in the Harvard Business Review.
In the post lockdown situation, we understand that management and finance will think carefully before approving any new cap ex spends. Pure Skies air cleaners pay for themselves in just 12-18 months, then deliver pure cost savings after that.
If that’s not good business sense, then we don’t know what is!
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