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Health Hazards of Gear Surface Finishing: A Call for Improved Air Filtration by Hengst Filtration’s Innovative Solutions

Health Hazards of Gear Surface Finishing: A Call for Improved Air Filtration by Hengst Filtration’s Innovative Solutions

Gear surface finishing is a critical step in the production of gears, ensuring precision and durability in these mechanical components.

However, the process poses significant health risks to workers due to the generation of dirt and dust particles. These hazards, if not managed efficiently, can lead to various respiratory and skin ailments among workers.

What is Gear Surface Finishing?

Gear surface finishing encompasses a range of processes focused on refining the surface of gears to meet specific requirements.

These processes include grinding, honing, lapping, and polishing, among others. Every mentioned step involves the removal of material to achieve the desired surface finish, dimensional accuracy, and gear tooth profile. These operations generate metal particles, abrasive dust, aerosol and coolant mist as by-products.

These particles can become airborne and pose health risks to workers if proper precautions are not in place. The suspended particulate matter which cannot be seen but sensed by the internal organs upon getting affected due to their presence in the air.

Health Hazards Faced by Workers:

Workers involved in gear surface finishing are exposed to several health hazards due to the nature of the process:

Respiratory Issues: The inhalation of airborne particles can lead to respiratory problems such as coughing, wheezing, and shortness of breath. Prolonged exposure to metal dust may also cause chronic conditions such as occupational asthma and pneumoconiosis.

Skin Irritation: Direct contact with metal particles and coolant fluids can cause skin irritation, dermatitis, and allergic reactions.

Workers may experience redness, itching, and inflammation, particularly in areas of prolonged contact.

Eye Irritation:  Metal particles and coolant mist can irritate the eyes, leading to discomfort, redness, and watering. Prolonged exposure may increase the risk of eye infections and long-term damage to vision.

Long-term Health Impacts: Chronic exposure to airborne contaminants in gear surface finishing facilities has been associated with more serious health issues, including lung cancer, cardiovascular diseases, and neurological disorders.

Introducing Hengst Filtration Solutions:

To address these health hazards effectively, companies must invest in advanced air filtration systems. Hengst Filtration offers two innovative products designed specifically for the metalworking industry:

1. MultiAir eco:

The MultiAir eco is a compact air duct filter designed for the extraction of oil-based cooling agents. It features a range of benefits tailored to the needs of gear surface finishing operations:

• Safe filter function ensures efficient removal of airborne contaminants.

• Recirculating air mode complies with workstation limit values, ensuring a safe working environment.

• An innovative filter control system (MechaTronic EC) optimizes filtration efficiency and reduces maintenance requirements.

• Easy servicing and fast replacement of filter components enhance operational efficiency.

• Suitable for installation on processing machines, ensuring effective capture of contaminants at the source.

The MultiAir eco is an ideal solution for metal works, CNC tooling machinery, and process exhaust air systems, offering reliable protection for workers against airborne hazards (such as the aerosols causing breathing issues).

2. MultiTron Junior Premium:

The MultiTron Junior Premium is an electrostatic precipitator system designed for the separation of cooling lubricants, oil mist, smoke, and oxides.

Key features include:

• Modular structure allows customisation to specific requirements, ensuring optimal performance.

• A highly efficient fan with low energy consumption reduces operational costs.

• A patented filter control unit (Multironic) with selfcleaning insulators maintains filtration efficiency over time.

• Compact design requires minimal space for installation, making it suitable for small-scale operations.

• Return air operation ensures compliance with maximum exposure limit values, safeguarding worker health.

By investing in Hengst Filtration’s advanced solutions, companies can mitigate the health risks associated with gear surface finishing and create a safer working environment for their employees. These products make the air breathable for the workers working around at the workplace by removing the metal particles and the SPMs.

An Exclusive Interview with Mr Manish Khanna Business Development Head (India), Hengst Filtration

Mr Manish Khanna explained how the Hengst Filtration products can help prevent the hazardous impacts of surface finishing processes for the workers working on the shop floors.

He also adds the products are designed to keep the workplace clean by purifying the surrounding air which the people working are exposed to.

There are two types of metalworking fluids which act as coolants, of which one is mixed with water and the other is neat oil.

These oil-based lubricants extract the fumes in the atmosphere, eventually making the air clean and breathable.

The products are the state-of-the-art quality. Mr Khanna also told us how the demand for such products is increasing globally as every nation aims to reduce its carbon footprint in the present time.

When asked about the rising technological trends in such products, he mentioned that their smart multitron controller, which is IoT-enabled with advanced features displays the user all the live parameters of the air filtration device, and also contros the fan speed along with other requisite features.


Gear surface finishing plays a crucial role in ensuring the quality and performance of gears in various industries.

However, the process poses significant health hazards to workers due to generating airborne contaminants. To protect employee health and well-being, companies must prioritise the implementation of effective air filtration systems.

Hengst Filtration’s innovative products, such as the MultiAir eco and MultiTron Junior Premium, offer reliable solutions for capturing and removing harmful particles, ensuring a safer and healthier workplace for all.