News & Case Studies

How Does a Dust ​Collection System Work?

In its most basic form, LEV (Local Exhaust Ventilation) systems are industrial dust extraction systems designed to draw airborne dust particulate away from production areas to improve the air quality in a production facility. The dust extraction system reduces exposure to harmful inhalable fumes and dusts and helps comply with safety standards. Once airborne dust is captured and conveyed to a dust extraction filter unit, it is purified by being separated from the airstream. The air is then released back into the building or discharged externally to atmosphere. It is essential to control the level of respirable dust inside a production facility to prevent health hazards for your employees, and it should be regarded as a priority. This article will dive into your LEV system's key components and considerations.

• Dust Control

Scrap System Upgrade in Tight Shutdown Window

integratedAIR was appointed to design and implement a complete upgrade of an ageing scrap extraction and baler feed system within a high-output can manufacturing facility. The existing system was over 30 years old and no longer capable of supporting the site’s operational demands. The project required the full strip-out of the existing scrap system, installation of new air separators, ductwork, platforms, and controls, and preparation for the integration of two new balers, all within a strictly limited factory shutdown period.

• Ducting
• Scrap and Waste Extraction

Transforming Air Quality in a Steel Plant Process

integratedAIR Systems was approached by Marcegaglia UK, the largest steel manufacturer in Great Britain, to address persistent air quality issues arising from its tundish wrecking process. The client had been experiencing significant dust and fume emissions during tundish rotation, particularly in a small waste room below the operation. These emissions affected the working conditions for operatives and contributed to wider contamination across the melt shop and warehouse. The client requested a dedicated extraction system to contain and control these emissions, improving the environment throughout the facility.

• Fume Extraction
• Dust Control

Multi-Zone Hot Duct with Dust and Fume Extraction

integratedAIR, alongside our strategic partner DURR , was approached by a global leading canmaker for a site in Denmark operating an external regenerative thermal oxidiser (RTO) system. The client required a new RTO externally as the existing unit no longer satisfied the production requirements. Additionally, the existing ducting systems that fed into the old system had to be extended and modified whilst accommodating future capacity. With duct temperatures ranging from 70°C to 250°C across the system careful consideration had to be made to ensure high temperature ducting was properly insulated to avoid internal build-up of condensation within the ducting the challenge lay in designing a tailored system for the new hot ducting and a new fume extraction system with filter as well as relocating the existing filters to the new RTO area and changing all existing change over stacks on the roof during a set shut down period.

• Ducting
• Abatement Systems
• Fume Extraction

integratedAIR becomes an Employee Ownership Trust

​We’re excited to share a major milestone in the evolution of integratedAIR Systems—we are now an Employee Ownership Trust (EOT). This transition marks a significant step forward, ensuring long-term stability, shared success, and a future where our employees are at the heart of everything we do. integrated Systems 2025 EOT encompasses integratedAIR Systems and FabriSYS Engineering, our dedicated manufacturing facility. This change strengthens our commitment to innovation, operational excellence, and the industries we proudly serve.

Trim and Dust Extraction Upgrade

As part of a significant machinery upgrade, integratedAIR was approached by a major packaging manufacturer that had recently planned the installation of a new EMBA 175 Ultima inline converting machine. This high-end equipment presented new demands on the plant’s existing waste extraction infrastructure, calling for an equally advanced and efficient trim and dust extraction solution. integratedair was called in to assess the site and deliver a comprehensive system upgrade tailored to the increased air volume, corrugated scrap and dust management requirements brought on by the new machinery.

• Scrap and Waste Extraction
• Dust Control
• Ducting

New Baler for Streamlined Scrap Management

integratedAIR was approached by a client who faced a pressing need to upgrade their scrap management system by replacing a baler that had been in operation since the 1980s to address immediate operational needs while laying the groundwork for a more efficient scrap management solution in the future. As the existing baler comprised long-since obsolete parts, integratedAIR advised that the Austropressen DS-700 baler was the ideal replacement. However, integrating this modern equipment into a complex set-up that was outdated by decades presented a tough challenge.

• Scrap and Waste Extraction

Custom Conveyor Extraction System

integratedAIR was approached by a longstanding client in need of an efficient, cost-effective, and noise-controlled extraction system. The client’s request centred around collecting and processing trim waste from a conveyor belt with a system capable of merging two collection points and processing the media with minimal energy costs. To achieve the client’s goals within budget and facility constraints, integratedAIR’s design incorporated high-end equipment, a redesign of the ductwork layout, and insulation strategies.

• Scrap and Waste Extraction

Custom Fan Installation for Scrap System in Africa

integratedAIR was approached by a prominent beverage packaging manufacturer in Africa, which required a significant upgrade to its existing scrap extraction system. The company’s can-end manufacturing facility faced challenges due to the placement of critical fans on a mezzanine in the baler area. This area was congested and difficult to access, reducing the operating capacity and maintenance access to the fans. integratedAIR was tasked with providing a solution to improve airflow and accessibility by relocating and upgrading the scrap extraction system.

• Scrap and Waste Extraction

Bespoke Trim Extraction System for Corrugated Board Manufacturer

A major corrugated board manufacturer approached integratedAIR to design and install a modern trim extraction system to handle increased production capacity. The client supplies packaging products to local and national businesses, and rising demand—particularly from the e-commerce sector, required an upgrade to their UK facility’s equipment. The existing air conveyance system was outdated and unable to cope with the added load from a newly installed die-cut machine, necessitating a new, efficient solution.

• Scrap and Waste Extraction

Scrap Extraction and Air Filtration System

integratedAIR was approached by an overseas client in the Southern Hemisphere to design and install a dual-purpose system for collecting and extracting aluminium scrap from multiple trimmers and an oil mist extractor to evacuate oil fumes and improve the atmosphere at the plant. The project aimed to efficiently manage aluminium scrap from can production while ensuring compliance with environmental and safety standards. It was designed to integrate with the existing infrastructure and minimise downtime through a robust, continuously operating system.

• Fume Extraction
• Scrap and Waste Extraction
• Oil Mist Elimination

Bespoke Scrap Extraction System for Beverage Can Manufacturing

integratedAIR was approached by a long-standing client to design and install a scrap extraction system for their can-end manufacturing site in Eastern Poland. Several presses in this facility produce scrap aluminium in various shapes and sizes, requiring bespoke air conveyance and scrap handling methods to ensure the maximum amount of aluminium can be recycled.

• Scrap and Waste Extraction
• Dust Control

Dust and Fume Extraction System for Leading Composite Manufacturer

integratedAIR were approached by an international company specialising in composite products for the Aerospace and Aviation Industry; recent expansion at their site in Berkshire, UK required comprehensive dust and fume extraction solutions for new CNC machinery at their facility. Our Engineers quoted for a comprehensive fume and dust extraction system integrated with an Antares CNC machine to extract carbon-based particles from the composite product and surrounding work surfaces. As well as minimising contamination of highly precise parts utilised in the Aerospace industry, this dust control system ensures a clean working environment for employees in surrounding workstations.

• Dust Control
• Fume Extraction

Bespoke solutions for beverage can manufacturer in UK

integratedAIR Systems were approached by a leading metal packaging manufacturer who required several bespoke solutions to increase HVAC efficiency, maximise material recovery, and improve access in their UK-based facility. The primary issue for this client was various machines in their manufacturing process exhausting internally, causing the temperatures to get as high as 60°C in some areas; in particular, an air compressor was discharging warm air upwards directly on to decorated, pre-palletised cans on the production line causing concerns with contamination and quality of the product.

• Industrial HVAC
• Scrap and Waste Extraction

Trends which are changing the Corrugated Board Industry

Corrugated board manufacturers have seen a range of factors influence their industry over the last few years; from growing e-commerce to changing consumer preferences. Increased production requirements can make modernising your process with effective and efficient solutions an essential part of staying competitive.

integratedAIR receives SHAPA award for Export in 2024

Solids Handling and Processing Association AGM

Bespoke BlueClean® Dust Control with Additional HEPA Filtration

integratedAIR were approached by a leading brick manufacturing site in the North West of the UK to design an LEV (Local Exhaust Ventilation) system for the automatic setting machines within their facility. The building materials manufacturing industry is particularly at risk from harmful dusts like RCS (Respirable Crystalline Silica), and this client has a long-standing history of investing in continuous improvement initiatives in health and safety to ensure the wellbeing of staff across multiple sites. This client has worked with integratedAIR on a number of projects to successfully install a range of bespoke LEV systems that address common dust control issues, ensuring the long-term safety of their employees and protecting the longevity of their business.

• Dust Control

Scrap Systems for Manufacturers

integratedAIR Systems has been providing production waste and trim extraction systems since 2002 in a wide variety of industries looking to streamline their production line. Our waste removal systems are being used across the globe and in a wide range of industries and applications to increase efficiency, reduce labour costs, and increase profitability from recycling or upcycling their production waste.

Leading Brick Manufacturer Dust Extraction​ System

A leading company in the brick production industry approached the integratedAIR team to design an LEV (Local Exhaust Ventilation) system to remove potentially harmful dust from the surface of the bricks on both the Automatic Setting Machine (ASM) and the De-Hacker, prior to final palletising, wrapping and distribution of the finished product.

• Dust Control

Aluminium Scrap Extraction System for beverage can manufacturing plant

We were pleased to be able to visit the newly installed line three of a multi-line canning plant in the Czech Republic for a client with a range of integratedAIR Systems installed. This included scrap and trim collection, air conveyance, dust and oil mist filtration, and HVAC solutions for three production lines across the facility over 120,000 m2

• Dust Control
• Industrial HVAC
• Scrap and Waste Extraction
• Oil Mist Elimination

Dust extraction system at corrugated board facility

integratedAIR Systems have recently completed a bespoke dust extraction solution for a leading corrugated board manufacturer in Stockport. This system was designed to integrate seamlessly with existing machinery to extract dust from seven spigots on the EMBA Casemaker. Our client was seeing increased cleaning and related disruptions having a negative impact on the production volume of the facility. As a valued local supplier of corrugated boxes and packaging, our client was concerned this could have knock-on effects to their customer base especially in the run up to winter holidays.

• Dust Control

Bespoke LEV system for dried herbs

Our client is one of the largest producers of dried herbs in Europe, based in Norfolk, UK. Using state-of-the-art technology, they can harvest and process locally grown produce at incredible speed without compromising product quality, achieving a Grade AA rating from the British Retail Consortium (BRC). The system was expertly designed with our client's unique requirements in mind; our BlueClean® FP ULTRA filter unit was designed with a bespoke filtration area of 180 m2 using an anti-static oleophobic filter media to ensure maximum filtration efficiency.

• Dust Control

Why is dust control essential for laser and plasma cutting?

Both laser and plasma cutting machines use highly concentrated channels of energy to cut through a variety of materials including wood, some plastics, metal, fabrics, and rubber. Whilst some materials react well to laser and plasma cutting, others can smoke and burn, release sparks or gas, or produce toxic vapours. Laser and plasma cutting is a highly effective method of cutting a range of materials but must be practised safely, with adequate ventilation and protection put in place to control these hazards.

• Dust Control
• Fume Extraction

Maurice completes the final race of the 2023 BEC at Donington Park

The final race in the British Endurance Championship was held at Donington Park; Maurice demonstrated his sheer grit, determination, and staying power to finish 2nd in class in the British Endurance Championship.

Turnkey dust extraction and filtration

British Offsite are reaching new levels of speed, safety, and efficiency within the construction and design industry at their state-of-the-art manufacturing facility in Braintree, England. integratedAIR supplied a complete waste and dust extraction solution, from design to commissioning, for plasterboard offcuts and dust created during the production of wall panels.

• Scrap and Waste Extraction
• Dust Control

Heat and Moisture Extraction for Corrugated Board Manufacturing at Ribble Packaging

Founded in 1936, Ribble Packaging Ltd produces corrugated board for a global clientele spanning diverse sectors, from its base in Oldham. They recently contacted integratedAIR to help improve their production procedure as it was generating significant heat and moisture. Mitigating these elements is imperative to ensure a safe environment for the workforce as well as providing optimal conditions for the machines to function.

• Process Cooling and Heat Recovery

Wienerberger Clay Brick Production​

Wienerberger Ltd, the UK and Ireland arm of the world's largest brick manufacturer, is a leading supplier of building products, including bricks, roof tiles, pavers and blocks. One of their production facilities in East Manchester approached integratedAIR to conduct a survey to replace a worn-out dust extraction system for their high-speed roller in the Clay Preparation Plant. The current filter unit had been poorly designed, particularly on the filtered roof, and was badly corroded, allowing water to leak inside the filter casing making the filter unit unusable.

• Dust Control

integratedAIR Receives The King's Award for Enterprise

integratedAIR Systems has been honoured with the first-ever King's Award for Enterprise for International Trade. The company received the accolade in the category of International Trade. Successful nominations were publicly announced today (Friday, 21 April), on the late HM Queen Elizabeth II's birthday.

The Future of the Beverage Can Manufacturing Industry

The beverage can industry has seen increasing innovation in recent years; disruptions to the supply chain during the pandemic affected the mining of raw materials and consequent production, but also highlighted the global reliance on single-use consumer products from PPE to plastic bottles. Growing demand for a recyclable and sustainable solution led forward-thinking manufacturers to innovate new shapes, volumes, and designs of aluminium beverage containers as a lightweight and 100% recyclable alternative to plastic bottles. Recent reports suggest that a multitude of factors have influenced the future of the beverage can manufacturing industry, with post-pandemic consumer mindsets leading the way for this resilient and adaptable industry.

Understanding Dust Hazards in Brick Production

Understanding dust hazards in brick production is essential in ensuring a safe and successful manufacturing process. Dust can be a significant issue in brick production, as it can create an unhealthy environment for workers and contributes to air pollution. It is important to understand the sources of dust and the steps that can be taken to reduce dust hazards. Employers should implement effective dust control measures such as adequate ventilation and dust suppression systems to reduce dust hazards. Employers should also ensure that raw materials are stored properly and finished products are handled carefully. By taking these steps, employers can help to reduce dust hazards in brick production.

• Dust Control

Dust Control for Animal Feed Manufacturing: All you need to know

The animal feed manufacturing process has always been an area of concern regarding combustible dust. In the UK, the Health and Safety Executive (HSE) governs the animal feed processing industry through the Dangerous Substances and Explosive Atmospheres Regulations 2002 and Control of Substances Hazardous to Health Regulations 2002 (COSHH) to ensure safe work environments.

• Dust Control

Why You Need Dust Control in Bulk Solids Handling

Whether to prevent product loss or avoid health risks for operatives working in your production facility, managing and controlling air-born dust particulate is vital whenever bulk solids are handled. It is essential to control respirable dust to prevent health hazards for your operatives and should be regarded as a priority. Correctly designed dust control or LEV (Local Exhaust Ventilation) will protect your employees and ensure your production and processing facilities comply with legislation.

• Dust Control

Steel & Aluminium Trim Recycling System

integratedAIR Systems was commissioned to design and implement a steel and aluminium trim extraction system for a food canning factory in the Netherlands. There was no collection system from aluminium; therefore, a completely new recycling system was designed and installed next to the existing system.

• Scrap and Waste Extraction

Skeleton and Slugs Extraction System

integratedAIR Systems was recently asked to design, supply and commission a skeleton and slugs extraction system for a canning factory in Kentucky, USA.

• Scrap and Waste Extraction

Shell Press Extraction & Sweep Up Hopper System

integratedAIR Systems was selected to design and implement a shell press extraction and sweep up hopper system for a Can Factory in the Czech Republic. They are expanding their manufacturing line and needed a new system to keep up with supply demands. Efficient, well-designed scrap and waste removal systems are an essential part of high output production lines.

• Scrap and Waste Extraction

Scrap, Dust & Oil Mist Extraction in Salt Lake City

A new two-piece D&I can making plant located in Salt Lake City has been built to keep up with the demand for aluminium cans in the US. integratedAIR Systems was commissioned to design and install the scrap, dust, oil mist extraction and prefabricated fabricated skid systems to help the plant run more efficiently. integratedAIR Systems have supplied the first line system with future extraction of line two to be installed at a later date.

• Dust Control
• Scrap and Waste Extraction
• Oil Mist Elimination

Hot, Sprays and Cold Ducting System​

integratedAIR Systems was commissioned to design, manufacture and implement an above-roof hot, sprays and cold ducting system as part of a collaboration with DURR to better serve our end client's requirements for a VOC abatement system.

• Abatement Systems
• Process Cooling and Heat Recovery

20th Anniversary

Established in 2002, integratedAIR Systems celebrates its 20th anniversary of delivering high-quality air conveyance systems to manufacturing industries worldwide. Continuing success has enabled us to expand to four sites in the UK with the recent development of a Filtration and Services division. integratedAIR delivers a 'can do' attitude towards engineering solutions, aftercare and maintenance, ensuring that the systems we provide are made with longevity in mind.

First Canning Plant in Kazakhstan

integratedAIR System is thrilled to be part of the first canning facility in Kazakhstan – providing a scrap system, air filtration for wet can damage elevation system and decorator ink mist and over-varnish extraction system.

• Scrap and Waste Extraction

Why Is Dust Extraction So Crucial in​ The Workplace?

Any dust created in the manufacturing process can be hazardous for those working on an industrial site and potentially lead to significant health issues. We at integratedAIR Filtration help our clients find the correct dust extraction for their business and tailor on BlueClean® units to suit their unique needs. When dealing with the manufacturing process or raw materials, all industrial workers know they often produce harmful airborne contaminants. Dust and fumes are one of the leading causes of health problems in industrial workplaces; correct extraction systems are not only essential to meet workplace regulations, but they ensure the safety of your employees. If there’s one thing that many industries often fall short on, it’s proper dust extraction. Here are some reasons why dust extraction is so necessary for the workplace;

• Dust Control

Most Hazardous Occupations for Dust

Hazardous working conditions are a big concern for a lot of employers, especially in recent years. When it comes to dust and working conditions, this is now a significant concern for many businesses working in many sectors regarding health and safety. HSE (Health and Safety England) has reported an estimated 12,000 lung disease deaths each year linked to past exposures at work. With this in mind and the startling figures surrounding hazardous dust, at IntegratedAIR Filtration, we specialise in dust extraction units. Our mission is to keep our clients’ businesses safe, so here’s what you need to know about hazardous dust and the occupations at risk.

• Dust Control

Are You COSHH Compliant?

Thousands of employees across the United Kingdom work daily within hazardous environments. Risks need to be taken seriously, which is why companies should have compliance with COSHH regulations within the workplace. Every business needs to know about the Control of Substances Hazardous to Health Regulations (COSHH). COSHH compliance laws apply to nearly every business type, from work in offices to work on construction sites, factories, warehouses, hospitals, or schools.

• Dust Control
• Fume Extraction

Why is ATEX Vital?

At integratedAIR Filtration, we understand the importance of dust extraction units required for staying safe in hazardous working environments. It is essential to have a correctly designed dust extraction in ATEX environments. In areas where explosive atmospheres are identified, employers must specify the level of risk by assigning each area a zone classification, based on: How likely could an accident be? How often is the explosive atmosphere present? How long would any reaction last if it was to occur?

• Dust Control

Operator Spot Cooling for Beverage Can Plant

We were commissioned by a beverage can plant in Seville, Spain, to add to their HVAC systems. We introduced spot cooling over their operator areas, making working in warm climates more bearable for employees.

• Industrial HVAC

Corrugated Trim Extraction at Nuttall Packaging

We have been working with Nuttall Packaging since 2004, helping with the ongoing development of trim and dust extraction within their manufacturing process. Nuttall contacted us to help with trim extraction of their new machinery.

• Dust Control
• Scrap and Waste Extraction

Air System Modification Works for the Printing Industry

integratedAIR Systems was commissioned to design and implement an extraction system for a new Ferag Unidrum and Trimmer for a large printing factory based in the North West of the UK. The previous system we installed in 2003 and needed to be adapted to the accommodate the new expansion.

• Scrap and Waste Extraction