HYDRO Emulsion Mist Separator for High Aerosol Loads

The HYDRO emulsion mist separator is a powerful mechanical air-filtration system designed for industrial processes in which heavy emulsion mist, metalworking-fluid aerosols, smoke and general airborne contaminants must be safely removed from the process air.

The Hydro 12 to Hydro 60 series—and larger configurations—were developed specifically for applications in which conventional filtration technology is placed under severe strain by exceptionally high aerosol loads or highly water-based emulsions.

At the heart of the FMN-HYDRO series is the self-draining aerosol separator. Collected aerosols condense within the filter medium and are subsequently drained from the filter by gravity. This makes the Hydro filter particularly suitable for machining processes involving intensive use of metalworking fluids, wet mist and high liquid loads in the extracted air.

The Hydro filters can also be backwashed and reused several times, extending their service life and reducing maintenance requirements. Air volumes of up to 50.000 m³/h can be achieved.

Applications of the HYDRO Emulsion Mist Separator

The HYDRO is the right solution when the key requirements include extracting heavy emulsion mist from production processes, filtering metalworking-fluid mist, separating aerosols through a self-draining process, or removing smoke from machine tools.

The filtration unit is designed for machining processes that generate large quantities of wet aerosols and require the filtration system to operate reliably over extended periods.

Typical applications include CNC machining centres, lathes, milling machines, grinding machines, honing machines, transfer lines and automated production lines. The HYDRO series offers significant advantages over conventional filtration concepts, particularly in processes involving a high proportion of metalworking fluid, intensive mist emissions or highly water-based emulsions.

Typische Anwendungen

Extraction of heavy emulsion mist from CNC machines
Filtration of metalworking-fluid aerosols in metalworking processes
Air purification involving water-based emulsions and high humidity loads
Separation of smoke and mist from turning and milling centres
Use with grinding machines, honing machines and machining centres
Special version with a pre-filter for cast-iron and graphite machining

Group extraction for multiple machine tools
Central air-filtration systems for production areas
Retrofitting existing extraction systems when aerosol loads increase
Use in series production, contract manufacturing and mechanical engineering
Air-pollution control in production halls with high process loads
Reduction of aerosol deposits on machines and production-hall surfaces

Thanks to its modular design, the HYDRO series can be used not only as an individual unit but also as a scalable filtration system for larger air volumes. It is therefore suitable for individual machines as well as complex production cells and central extraction solutions.

Features of the Hydro Emulsion Mist Filter

The HYDRO filtration system combines robust housing technology with a multi-stage filter configuration optimised for liquid removal. The housing is made of 1.5 mm sheet steel and is welded to ensure a drip-tight construction.

Variable slide-in rails and guide rails are installed inside the housing, allowing the aerosol separators and final filter stage to be removed easily.

A key difference compared with standard emulsion mist separators is the integrated Hydro aerosol separator. It collects aerosols, combines them within the filter medium and discharges the condensed liquid again by gravity. This self-draining operation reduces the load on downstream filter stages and considerably increases their usable service life.

The individual filter stages are secured within each filter chamber using a four-point clamping mechanism. This prevents process air from flowing uncontrolled around the filter stages.

For clean liquid removal, the bottoms of the housings are designed as collection trays with drain connections. A siphon unit can be used to discharge the separated liquid in a controlled manner.

The maintenance doors feature continuously fitted Perbunan profile seals with steel cores. Star-grip screws press the doors against the housing to create a drip-tight seal. Internal drip guards reduce the escape of separated liquid when the doors are opened.

Your Benefits at a Glance

Self-draining aerosol separator for high liquid loads
Ideal for water-based emulsions and heavy aerosol loads
Hydro 12 to Hydro 60 series and larger configurations
Backwashable and repeatedly reusable Hydro filters
Extended service life thanks to the filters’ draining properties
Optional special pre-filter for cast-iron and graphite machining
Multi-stage mechanical filtration technology for emulsion mist and smoke
Regenerable pre-filter stages that can be washed or sprayed clean
H13 main filter in a V-shaped configuration
Fine-filter pocket as an additional filtration stage
Filter inserts designed to prevent incorrect installation
Four-point clamping mechanism in each filter chamber
Drip-tight welded sheet-steel housing
Collection tray with drain connection for controlled liquid removal
Connection option for a siphon unit
Variable airflow direction, with extraction from the left or right
Wall brackets
Height-adjustable floor supports

Adjustable floor supports
Wall brackets
Maintenance doors with Perbunan profile seals and steel cores
Drip guard to prevent liquid discharge when the doors are opened
Mounting rails positioned according to customer requirements
Optional analogue or electronic filter-contamination indicator
Option for additional pre-separators in the extraction hood
Energy-efficient, variable-speed ECblue motors
Electronically adjustable airflow capacity
Optional wireless programming of settings using Android and iOS devices
Integrated motor protection and active temperature management
UL approval
Variable filter configuration for changing applications
Retrofittable for operation as an electrostatic filtration system, for example when changing the metalworking fluid from emulsion to oil
Scalable through a modular system and additional filter modules
Optional constant-volume-flow control

With this equipment, the HYDRO is a particularly robust solution for manufacturing operations in which conventional mist separators quickly reach their limits because of high humidity, heavy aerosol concentrations or frequent filter loading.

Benefits for the Operator

The HYDRO emulsion mist separator helps operators reliably clean process air while reducing maintenance requirements.

Its self-draining filtration technology ensures that separated aerosols do not remain permanently within the filter medium. Instead, they are removed through condensation and gravity drainage. This reduces the load on the filters and extends the service life of the Hydro filter elements.

For production companies, this means fewer unplanned maintenance interruptions, more stable extraction performance and improved air quality around the machinery.

Particularly in metalworking operations where metalworking fluids are used continuously, the Hydro system helps capture mist, smoke and liquid residues in a controlled manner.

Another advantage is its retrofit capability. New filter media, EC motor technology and adapted filter stages can be designed so that older systems can also be technically modernised. The HYDRO series therefore remains suitable for long-term use even when machining processes, metalworking fluids or required air volumes change.

Applications of the Filtration System

Machine tools with high metalworking-fluid input
CNC machining with heavy aerosol loads
Machining with water-based emulsions
Grinding processes involving wet process air
Cast-iron and graphite machining with additional pre-filtration
Production lines with multiple machining centres

Production halls with central extraction systems
Mechanical engineering, metalworking and series production
Automotive suppliers and contract manufacturers
Systems with frequently changing process conditions
Modernisation of existing emulsion mist separators
Air-filtration systems requiring modular expansion

The HYDRO emulsion mist separator for high aerosol loads is therefore more than an individual mist separator. It is an expandable filtration system for industrial air-pollution control.The combination of a backwashable Hydro filter, an H13 final filter and a variable filter configuration makes the system particularly flexible.

HYDRO for Self-Draining Aerosol Separation and Energy-Efficient Airflow Performance

The Hydro series was developed for demanding processes involving high concentrations of liquid droplets and fine aerosols. While standard filter media can become saturated more quickly under high humidity loads, the Hydro filter operates with a draining effect. Liquid collects in the medium, condenses and is discharged from the filter again. In combination with variable-speed EC motors, the airflow capacity can be electronically adjusted to the actual demand. This allows the system to operate energy-efficiently without moving unnecessarily large volumes of air. Additional optional functions include: Automatic airflow control, Constant-volume-flow control, Mirrored system configuration, Analogue or electronic filter monitoring

Technical Specifications of the HYDRO Emulsion Mist Separator

The following overview provides guidance on the most important unit sizes. The actual system should always be designed according to the required air volume, type of emissions, metalworking fluid, machine enclosure, ductwork, pressure loss and desired operating characteristics.

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HYDRO-V Emulsion Mist Filter Product Overview

Product	airflow max. m³/h	Power in kW	L in mm	T in mm	H in mm	D (Ø) in mm
HYDRO-12	1.200	2,2	1.387	470	650	150
HYDRO-30	2.800	3,9	1.500	920	650	250
HYDRO-60	5.000	5,6	1.800	920	1.225	350