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The buzz words of the 70s - Energy Shortage - have been replaced by the buzz words of the 80s - Rate Shock. As new electric generating plants come on line, the aircraft plating industry, along with the rest of the public, is seeing huge increases in their electrical energy costs. While many of these costs, such as electrical energy for rectifiers, are fixed by the process, other large costs, such as power ventilation requirements to comply with the Occupational Safety and Health Administration (OSHA) Regulations, are not unalterable. Designing an economical ventilation system does not mean compromising the worker’s safety nor violating OSHA requirements. Rather, OSHA guidelines specifically outline methods of reducing the ventilation requirements. This paper investigates several of these alternatives, including adequate hood design, push-pull ventilation systems, covering the process solution and operational methods that can greatly reduce the ventilation requirements.