It has been discovered that people are beginning to embrace the use of air purifiers as compared to past years. There is only factor that can be traced to such a positive development. This is how there has been great awareness about such devices with regards to their potentials when used in homes or offices. In a survey carried out, it was revealed that over 90% of Americans spend majority of their time indoors. This implies there is a growing need for the use of air purifiers far more than ever before.
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The challenge
The major issue about air purifier is that most people are still asking lots of questions about whether it is safe to make use of or not. There is only one problem that can be responsible for such negative assumption/thought. This is the fact that they are yet to fully understand how these devices are produced/manufactured. In case you are amongst these individuals, there is no need trying to rack your brains about where to find out more regarding an air purifier production.
The reason is that you’ve come to the right place where every detail about how air purifiers are being produced will be revealed. There is no doubt that after this post, you will start the process of getting one that can meet your needs today.
What is an air purifier?
Before delving into the main details of this post, it is important you understand what an air purifying device is basically all about. This is a device that has been designed to ensure that indoor air pollutants are captured. Whenever you are indoors, there are airborne particles around. Sometimes you may see them but other times, they may be invisible to the naked eyes. When these are inhaled, they can cause health complications in your system. It could be problems related to sneezing, coughing or breathing difficulty.
These are the problems that air purifiers are being manufactured to fight against in homes and offices. Their primary function is to ensure that the quality of air in such environment improves. There are devices which have the potentials of purifying air at an accuracy rate of 99.7%. Some components of the air are natural gas, nitrogen, and oxygen. It has been discovered that there are times when other air pollutant particles can mix up with these components. These could be bacteria, microbes, virus, artificial gas, dust, pollens, dust, ashes, and hair. The list is endless when it comes to identifying pollutants that can affect the condition of air indoors.
This is where an air purifying device will prove to be useful. It has been created to spot these air pollutants. There are some which can even take that extra step in destroying them thereby ensuring they don’t return to the air again. The first air purifier can be traced to 1963. It was the idea of 2 brothers from Germany who decided to come up with an innovation that will improve air quality in German homes. The technology has advanced beyond such stage today with some devices having smart features to make life more comfortable for users.
The production process
Talking about how an air purifier is produced, there are lots of factors involved. This post will be trying to explain each of them in the subheadings below.
Factors producers/manufacturers consider
There are factors producers of air purification devices take into consideration before commencing the production process. Some of these will be highlighted below:
The purpose of the air purifier
This is very important as such will determine whether the needs of end-users will be eventually met or not. It is true that air purifiers have been designed to ensure improvement in air quality around homes and other indoor environments. However, their functions are slightly different. Companies decide at an early stage the functions they would like such devices to perform. For instance, there are air purifiers which have been designed to capture dust, pet dander, pollens and others from the atmosphere around the home. There are also air purifiers which help to get rid of smoke from cigarettes.
When a company makes the decision about which role an air purifier will carry out when used, such will help in determining the components to be included. When it comes to air purifiers, they are of various types which is one thing producers have managed to differentiate in a perfect way. The materials or components being used in the production process will be determined by the type of device a company has decided to manufacture. Producers have basically divided them into 2 categories in recent times. These are catalytic oxidation and filtration absorption air purifier.
Filtration absorption air purifiers are being produced to get rid of harmful gas in the atmosphere. They can also be helpful in the case of pathogenic microorganisms. These devices can purify the air through production of substances using catalytic as well as oxidative decomposition. Air purifiers such as these are majorly aimed at ensuring dangerous gases as well as pathogenic microorganisms are gotten rid of from the atmosphere.
The features
It is important you know that air purifiers tend to vary in terms of their features. This is probably why some are pricier than others. A company tries to take various factors into consideration before deciding what features an air purifier should have. For instance, the level of noise generation for various settings will be determined. There will also be decision on whether the device should have smart features like low electricity consumption, Wi-Fi connectivity and more.
No producer of an air purification device who doesn’t take all of these factors into consideration before starting out. Another critical factor that is mostly considered is the size of the device. Some producers have various designs that can fit into different spaces. There are people who have this wrong belief about air purifiers being produced for only large spaces. This isn’t true as producers have air purifying devices which can be used in small rooms too.
According to a producer, determining the size of an air purifier that should be manufactured before production process starts is very important. There are companies which even conduct online and offline surveys in order to determine the right size of air purifiers to be produced. A manufacturer once explained that companies invest heavily in market research in order know the size which end-users may want in their homes and offices. The reason is that any mistake of manufacturing what won’t sell can make them experience huge losses.
Their Components
The idea of which components are to be included in an air purifying device is also important for a successful production process. For instance, producers need to determine what kind of filters are to be installed in the air purifiers. There are various questions which need to be answered before the ideal components for an air purifier can be gotten. One of them is the category of end-users being targeted.
In the above case, producers may likely decide to put filters that of moderate/medium quality in order to ensure the device is affordable. There are different types of filters being installed in air purifiers. While some are permanent, others need to be replaced within 3-4months. The air purifiers which come with permanent filters always command prices that are higher as compared to those which have replaceable filters.
Most air purifiers in the market come with replaceable filters. The reason is that producers have discovered they are the mostly affordable for end-users. In other words, their demands are higher when compared the other group of air purifiers which come with filters that are permanent.
Its design
When it comes to design, producers are always trying to ensure functionalities of an air purifier aren’t compromised in any way. As an end-user, you may find the design of such device to be appealing. However, producers tend to look beyond such as they always ask some certain questions pertaining to how their air purifiers are designed. For instance, they try to consider how such devices will fit into small and large rooms without too much spaces being taken.
Before production commences, a company can make decision about whether its air purifier would be designed to be mounted on walls, hanged on ceilings, wearable or even mounted on desktops. This is very crucial given that it will be used in determine how much space the supposed air purifier will consume around the home and office.
It should be noted that when it comes to design which is one of the final stages of producing an air purifier, there is always variation in terms of complexity. This means that depending on the type of air purifier to be produced, a manufacturer may find it to be more complex than others. HEPA filter air purifiers have been discovered to be one of the easiest with regards to design. There are two major factors which can influence how the HEPA filters are to be designed. These are particles which are expected to be removed and required rate of air flow. Finer particles can be removed by finer pores.
Please note that for finer particles to be collected, such can make the filter clog sooner. This will lead to replacement earlier than expected. The design process is going to involve glass fiber diameter specification. The filter fabric mat density will also be taken into consideration. Most producers include binders in their HEPA filters to make them more effective while working. However, these don’t usually last long. The reason is that they make the filter clog much sooner.
Electrostatic precipitator design process seems to be more complicated than that of heap filters explained above. For home electrostatic precipitator, there are two components which they usually involve. These are ionizing component and collecting component. The former involves the creation of electron cloud while the latter is all about when the particles get pulled out from the air. There are parallel steel plates which the collecting component consists of. Some carry direct voltage while the others are grounded. Alternate plates become positively or negatively charged. Ionizing unit consist of thin wires that carry around 25,000 volts.
It is the positively charged which carry out the role of inducing electron flow between adjacent ionizing plates and the wires. Due to the wires having high voltage, electrons will be pushed towards it with high gravity. In this process, there is acceleration of electrons to high velocities. For instance, once dust particles come in contact with the wire while the device is working, there will be a collision between the particles’ electrons and electrons in the device. This will lead to a process where the former group of electrons will be killed. It is an instance, where there is a collision between negatively and positively charged ions. This is a typical example of how an ionizing air purifier has been built to work.
Raw materials
The manufacturing of air purifiers involve the use of various materials. It all basically depends on the type of air purifier which a producer has decided to create. However, there are instances when both electrostatic precipitators and HEPA filters make use of the similar materials. These could be plastic material, electric fan, control switches, and the filter. Each of these materials will be explained further below:
Plastic material
Every air purifying device comes in plastic cases. This is what is used in providing finishing touches to ensure they are appealing and can contribute to making homes appear beautiful. The idea of plastic case is to ensure safety. In other words, it is to ensure that there is less risk of electric shock in cases when there seems to be an issue with electrical connections in such air purifier.
Electrical fan
The electrical fan performs a very important role when it comes to how the air purifier will work. it helps in the process of effective filtration.
The filter
It is the material which ensures pollutant particles in the air are captured and destroyed by the device. Filters can usually come in various types. For instance, there are some which can be replaced after a period of 3-4months. There are permanent filters which only require periodic maintenance to function optimally. Producers usually decide on which of them to include in their air purifiers before releasing them to the market. Most of the time, such decisions are based on consumer report and survey.
Control switch
Every air purifying device has control switch. This is what ensures the fan is controlled at varying speed levels to make their filters work fine. They are also responsible for making the devices get turned off and on whenever the need arises.
The materials usually used for their cases are plastic. These could come in the form of polypropylene, polyethylene, polyvinyl chloride or high impact polystyrene.
Types of air purifier to be produced
This is another integral process of air purifier production. The market is filled with different types of air purifiers. Most of the companies make this decision based on consumer report. In other words, the decision to produce a particular type of air purifier will be greatly dependent on consumer report. Below are the various types of air purifiers that can be produced.
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1 – Ultraviolet air purifiers
These devices are very common amongst companies. They have been designed to get rid of air pollutants through the use of ultraviolet light. These could be pathogens, bacteria, harmful viruses, and others. Companies started producing this type of air purifying device once hospital began to make use of UV lights in getting laboratories and rooms of patients disinfected. There are residential and commercial UV air purifiers. The former is perfect for spaces that are small while the latter is great for commercial use.
UV devices have one major aim or purpose. This is getting rid of germs and mold in order to ensure illnesses are prevented. Through this light, cells can either become incapacitated or killed. For this device to be produced as expected, the company will need to understand how electromagnetic radiation works. There companies which have discovered that UV light has various sources. These could be mercury-vapor lamps, black-light lamps, phototherapy, sun beds, and sunlamps. A perfect understanding of these will help a company know which UV light is actually ideal.
There is always the fear that UV air purifiers have been designed to produce ozone while working. This is far from the truth as most of them aren’t. As a matter of fact, most of these types of air purifiers have been made to go through some rigorous and strict testing phases in order to ensure 100% safety for end-users. This means there is no need panicking about their safety.
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2 – HEPA Air Purifiers
These air purifiers are becoming increasingly popular amongst others in recent times. They are devices which have been produced with advanced filters to ensure the quality of air improves. Unlike the UV air purifiers mentioned above, the filtration process of these devices is done through usage of filters. Most of the companies include HEPA filters in their air purifiers. The reason is that they have been discovered to be effective and safe to make use of without any fear of health complications. For instance, HEPA air purifiers have an accurate rate of around 99.7% in the aspect of removing pollutant particles.
These forms of air purifiers are usually produced to help people suffering from allergies. When these devices are produced, there are lots of factors a company takes into consideration. These could be the nature of the filter, its cost and others. It all depends on the target market. For instance, a company can produce cheap HEPA air purifiers. The filters of such devices can be easily replaceable after a period of 3-4months. On the other hand, it can decide to manufacture permanent filters. The former option is always expensive after being produced. However, it can help to save money in the long run.
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3 – Activated Carbon Air Purifiers
Through the heating of carbon source at extremely high temperatures, these devices are produced. These air purifiers are produced to ensure harmful gases are removed from the air. Another name that they can be known as is activated charcoal air purifiers. These forms of air purifiers may not be common in the market but they have proven to be effective. A manufacturer once claimed that the reason why they produce these devices is the fact that it has been discovered how house products/items release volatile organic compounds.
There are some which are produced with HEPA filters to ensure complete purification of air. The truth about Activated Carbon Air Purifiers is that they are unique amongst other devices being produced. The reason is that HEPA filters are always included for the removal of gases, smoke, fumes, chemicals, and odors.
Initially when Activated Carbon Air Purifiers got introduced, they weren’t as effective as they are today when it comes to air purification. It is a technology that companies have spent millions of dollars perfecting over the years. This dates back to when it was first adopted by the Egyptians who made use of it in getting rid of odors which are related to infections.
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4 – Ionic Air Purifiers
These air purifiers can also be referred to as ionizers. They are a typical example of how technology has advanced when it comes to the field of air purification. Formerly, companies were only used to producing activated carbon and HEPA filters air purifiers. Due to series of research, there was need to produce something much better that people would feel more comfortable making use of. This gave birth to the production of ionic air purifiers. They are devices which have been produced to ensure the emission of negative substances into the air.
These will then produce substances will get attached to air pollutants such as pet dander, pollen, mold and dust. There are companies which include electrostatic precipitators in their ionic air purifying devices. These ensure that particles which are positively charged are trapped in such device. Most of the time, these devices are produced to be used in large spaces in homes and offices. Companies manufacture these forms of air purifiers to ensure that are available to all and sundry.
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The production process
Once everything is in place as explained above, the production of air purifier will then commence. Below are the processes or stages through which the major components are produced.
Producing the case
Stage 1
Just as explained above, the cases can be in the form of materials such aspolypropylene, polyethylene, polyvinyl chloride or even high impact polystyrene. Any one chosen will get fed into hopper. It will also be heated up to a melting point of around 150-310°C (300-590°F).
Stage 2
The molten plastic is going to get injected into the case’s mold. Please note that this process is carried out under intense pressure. In most cases, tool steel is where the mold is gotten from via a mold maker which is highly skilled. The mold has vents which helps to ensure air escapes just as the plastic is entering. At this point, the designer of such mold will ensure that the filling is even. Furthermore, air will have to escape in the right amount. This will avoid a situation whereby the finished part will have some voids or bubbles.
Stage 3
Water is going to be forced via channels which have been built into such mold for the transference of heat. This will move from plastic (molten plastic) to the environment. The mold will open once this part becomes cool.
In case you don’t seem to understand this process. The above explanation is all about the stage where an air purifying device takes its shape. It is a process where it begins to take the shape which a producer expects. Before it commences, most manufacturers would want to ensure that its shape is first of all drawn.
The fan
Through the fan, it becomes possible for air to be pulled via the device. There is nothing technical about adding fan as a component of this device. Some companies manufacture their own fans while others may decide to buy from sellers. The major components of a fan are 4blades and electric. Through the use of steel screws, the fan gets attached to such case.
HEPA filters
The HEPA filters are very important when it comes to air purifiers working as expected. In this stage, there is creation of the fibre glass which make up the HEPA filters. It can either be made to pass through molten plastic or glass. Due to their diameters being very tiny, the end product of fiber glass will become cool almost instantly. It will also become hardened at this stage.
The spinning nozzle at this point will be moving back and forth. This will lead to formation of a web by the glass fibers. The filter material’s thickness will be determined by the speed at which the conveyor belt is working. When the conveyor belt is slow, such will lead to the building up of more fiber glass on the belt.
Through melting as well as cooling, the fibers will begin to bond. As such conveyor begins to make progress, there will be the spraying of latex binder on the fabric. This is usually to ensure additional strength is available. A producer can decide to choose any size of fabric. Sometimes it is based on customer survey or review.
Once HEPA mats have been formed, they will then get folded into a folder that is automatic. These usually takes accordion pattern. Its standard filter measurement will be around 50ft2 (5m2). This will then get enclosed into a space that is small. The filter which is in accordion pattern will then become enclosed with the aid of filter case which is usually characterized by open wire grid. In other to ensure the filter is properly supported, this filter case will be been built.
Construction of electrostatic precipitators
- In order to ensure Electrostatic precipitators are constructed, steel plates are enclosed in a casing made up of plastic. This process is usually carried out manually. These plates will be arranged in a manner that they become parallel to each other while encased.
- There will then be connection of wires for the alternation of plates. This will ensure positive direct current with high voltage can be applied to such plates. Other plates will then become grounded.
- In order to get the ionizing unit constructed, diameter wires (small) will be made to pass through the collector plates’ front.
- There is a voltage transformer which will become fixed to precipitator case thereby converting household alternating current (115 volts) into direct current (high voltage). The voltage is expected to be running both ionizing wires and collector plates that are positively charged.
Constructing activated carbon filter
A major component of the activated carbon filter is foam or carbon-impregnated cloth. In order to manufacturer this, there is infusion of the raw materials using activated carbon (powdered).
The carbon filter will then be used in getting the HEPA filter wrapped. This can either be from its outside or inside. It is usually what determines the extent to which the filter will be able to catch smaller particles in the air.
The assembly stage
This stage can only become possible once the above stages/processes have been completed. The components of an air purifying device are very few. This is the primary reason why they can be bench assembled. It involves a process whereby individual component are being assembled manually by a professional.
It is an easy process once the others have been successfully completed. For instance, assembling the fan won’t be difficult given that it is already attached to a particular case. In the case of a standard air purifier, the components could be switch, carbon filter, particulate filter, fan and casing. Just as explained above, this stage involves putting each of these components together to ensure they work optimally. It is a stage that is done by someone who is skilled in assembling of such components. There can also be another professional to check whether they have been properly assembled or not.
Quality control stages
In order to ensure the air purifier meets the needs of end-users, it is important that it goes through a process of quality control. There are different types of quality control approaches. It all depends on the one that can align with the goals and objectives of a manufacturer.
Quality control is a process by which a producer adopts some measures to ensure the air purifier which has been produced has met the required guidelines (both internal and external). Also, it is to know whether the needs of end-users can be met without any compromise or not. With these processes in place, there is always assurance that the devices being produced will be of high quality. Below are some of the steps for effective quality control of manufactured air purifiers.
Step 1- Setting quality standards
In various industries, there are standards or guidelines which are expected to be followed to ensure goods produced are safe for public consumption or usage. It is the same with that of air purifying devices. For instance, when it was discovered that air purifiers which generate ozone while working can cause further health complications in the long term for consumers, several measures were put in place to ensure producers are creating safe devices.
In this case, the air purifying device which has been produced will be examined to ensure it has met such requirements. This will be in line with the various stipulations according to government policies. It is a process to ensure the health of consumers are protected any harmful device. The device will be thoroughly checked in terms of features and functionalities to ensure there won’t be any complications once it is used.
Step 2 – Making a decision on quality standard
Before the air purifier will be produced, a company will have to decide on which of the quality standards it would want to focus on. This is the stage whereby the producer will try to ensure the final product has been in line with set goals and objectives.
It is a stage whereby the product will be reviewed to find out whether there are any lapses. For instance, if the air purifier which has been produced is to have some specific features like replaceable filters, this is where such will be checked. The producer will want to find out whether the replaceable filters are of very high quality.
The reason for this stage is to ensure the device delivers in terms of quality and features as claimed. Reputable producers try to find out whether the quality of a component will have to be improved or not. This is where any correction or adjustment will be made before the product is finally allowed to go through the next stage of the quality control.
Step 3 – Checking operational processes
This is a very important process in the quality control stages. It is a stage where the air purifier will be well – observed to ensure every complaint is addressed accordingly. The reason for checking operational processes is to ensure the product is improved on a consistent basis. According to expert, this is a continuous stage that every quality product is made to go through even after being released into the market.
The reason is that it is from this stage, the air purifying device will be upgraded on a continuous basis so as to meet the demands of the changing times. A lot of comparisons are made in this stage. For instance, the producer of such device will compare its benchmark against actual results to find out aspects that require improvement.
Step 4 – Reviewing results
This is another crucial stage that can help improve the quality of such device in order to meet market expectations. In order to review results, it will be made to go through beta testing. This involves third and independent parties being allowed to test the air purifier. They will be expected to give unbiased reviews eventually.
It is the duty of the company to review these results in order to find out areas that need to be addressed before the device will be finally released into the market. It is a stage where feedback will be received from beta testers.
There are several ways that this can be done. These could be allowing people to have access to such devices after answering some survey questions or even offering them at prices that are highly discounted. This isn’t a problem though given that there are always people who will be willing to give their views on such devices.
Step 5- Making improvements
This is the last stage of quality control. It is an accumulation of the above steps to ensure set goals and objectives have been achieved when it comes producing an air purifying device that can meet vary needs of end-users without any compromise. It is a stage where reports and feedbacks will be objectively analyzed with a view to ensuring adjustments are made.
A reputable air purifier manufacturer will ensure none of these quality control stages is skipped since they determine how the product will perform amongst others in the market. In other words, each of them is very important.
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Conclusion
Based on the above, it is very obvious that the production of air purifying devices usually involves various stages which manufacturers go through. The major aim is to ensure the product is up to the required standard as stipulated by the government/regulating bodies.
The most important stage of production is quality control. It is the reason why manufacturers in various ecommerce platforms usually try to make it clear when their air purifiers have gone through various means of quality control. This is why you need to always look out for any device you plan purchasing. It is the only way of getting something that will live up to its claims.
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