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Case Study: Torch Cutting Marketing

Solutions for Scrap Yards – A

IT Services

Business Administration

Path to Compliance and HR Management

Efficiency Engineering

Soft Skills

Adam Andrews
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A.C.T. Dust Collectors - Custom Engineered Solutions + Follow
Published Nov 21, 2024

Case Study: Torch Cutting Solutions for Scrap Yards – A Path to Compliance and
Efficiency

The Challenge of Torch Cutting Scrap Metal

Torch cutting in scrap yards is a physically demanding process, often performed

under tough conditions. The task involves using hand-held torches to reduce
large pieces of scrap metal into manageable sizes for remelt. While it's effective,
the process generates substantial smoke and heat, making it a challenging job
both environmentally and operationally.

Typically done in open spaces, torch cutting may seem simple but often clashes
with environmental regulations. Agencies such as the EPA and OSHA have strict
guidelines around air pollution, which can result in fines, shutdowns, or even
lawsuits if not followed. Scrap yard operators are, therefore, forced to find ways
to capture harmful particulates and smoke, ensuring compliance while keeping
their operations running efficiently.

A Spectrum of Solutions: Torch Cutting Backdrafts vs. Enclosed Buildings

To mitigate the environmental risks of torch cutting, companies have two primary
options: a torch cutting backdraft or a stationary/movable building. Both solutions
require properly sized dust collection systems to capture smoke and particulates,
but they differ significantly in cost, complexity, and operational impact.

1. Torch Cutting Backdrafts

Backdraft systems are a more cost-effective and timely solution. These partially
enclosed structures are ducted to a dust collector, allowing operators to torch
metal toward the booth, which captures approximately 80% of smoke and
particulates, depending on wind conditions and proximity to the booth.

- Pros:

- Lower cost compared to a fully enclosed building.

- Shorter lead times and easier installation.

- Demonstrates a proactive approach to OSHA and EPA compliance.

- Cons:

- Operators are still exposed to weather conditions (rain, snow, heat).

- Limited capture distance, requiring multiple booths to ensure continuous

workflow and reduce downtime.

2. Torch Cutting Buildings

While more labor-intensive and costly to implement, a torch cutting building—

whether stationary or mobile—offers 100% smoke and particulate capture when
equipped with the appropriate dust collection system. This solution allows for bulk
processing of scrap metal on a mass industrial scale.

- Pros:

- Complete smoke and particulate capture.

- Optimized operational flow for large-scale processing.

- Cons:

- Higher initial cost.

- Longer lead time and significant space requirements.

Case Study: A.C.T.’s Torch Cutting Solution

One of A.C.T.’s clients was facing imminent shutdown due to excessive smoke
and particulate emissions from their torch cutting operations. Over two years, the
client tried various solutions from competitors but none met EPA or OSHA
standards. Frustrated, they contacted A.C.T. to develop a compliant solution.

After conducting a comprehensive site visit, we worked closely with the client to
design a tailored solution that minimized downtime and met regulatory
requirements. The final design involved a 48,000 CFM double air management
module ACT 5-120 dust collector. From final drawing approval to installation, the
process took just 3.5 months.

The results were immediate and effective. The system reduced emissions to
compliant levels, allowing the client to avoid fines, shutdowns, and lawsuits. After
two months of continuous operation, the filters had settled into about 30-40% of
their lifecycle, with filter replacements scheduled every six months—a common
cycle in high-output operations.

Why A.C.T. Succeeded Where Others Failed

Our approach wasn’t just about providing a product. We partnered with the client
to fully understand their operation, spending hours in person refining the design.
This included everything from formal presentations and CAD drawings to hands-
on modeling, to visualize the solution. The result was a custom solution that fit
both the operational needs and regulatory demands of the client.

The Importance of Proactive Solutions

While a full torch cutting building is the ideal long-term solution for many
operations, it may not always be feasible immediately. In such cases,
implementing a torch cutting backdraft as a temporary or supplementary measure
can be a smart move. Not only does it satisfy immediate regulatory requirements,
but it also allows time to design and implement a more permanent building
solution, using components like dust collectors that can be repurposed later.

As a CEO, safeguarding your operation from fines and shutdowns is critical, and
proactive solutions ensure business continuity while keeping regulatory bodies at
bay. While compliance may seem like a challenge, the right partner can turn it
into a competitive advantage. A.C.T. can help guide you through the complexities
of meeting environmental standards while maximizing operational efficiency.

---

Next Steps

If your scrap yard is facing regulatory pressure or looking for ways to enhance
your torch cutting operations, reach out to A.C.T. for a tailored consultation. Let
us help you design a solution that protects both your business and the
environment.

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