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Case Studies

The latest from integratedAIR Systems — project case studies, company news and industry insight.

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All systems Abatement Systems Ducting Dust Control Fume Extraction Industrial HVAC Oil Mist Elimination Process Cooling and Heat Recovery Scrap and Waste Extraction
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All industries Beverage Can Chemical and Solvent Corrugated, Carton and Board Industries Packaging and Containers Print and Paper Steel
  • Scrap System Upgrade in Tight Shutdown Window

    Case Study

    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
    View more: Scrap System Upgrade in Tight Shutdown Window
  • Transforming Air Quality in a Steel Plant Process

    Case Study

    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
    View more: Transforming Air Quality in a Steel Plant Process
  • Multi-Zone Hot Duct with Dust and Fume Extraction

    Case Study

    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
    View more: Multi-Zone Hot Duct with Dust and Fume Extraction
  • Trim and Dust Extraction Upgrade

    Case Study

    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
    View more: Trim and Dust Extraction Upgrade
  • New Baler for Streamlined Scrap Management

    Case Study

    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
    View more: New Baler for Streamlined Scrap Management
  • Custom Conveyor Extraction System

    Case Study

    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
    View more: Custom Conveyor Extraction System
  • Custom Fan Installation for Scrap System in Africa

    Case Study

    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
    View more: Custom Fan Installation for Scrap System in Africa
  • Bespoke Trim Extraction System for Corrugated Board Manufacturer

    Case Study

    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
    View more: Bespoke Trim Extraction System for Corrugated Board Manufacturer
  • Scrap Extraction and Air Filtration System

    Case Study

    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
    View more: Scrap Extraction and Air Filtration System
  • Bespoke Scrap Extraction System for Beverage Can Manufacturing

    Case Study

    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
    View more: Bespoke Scrap Extraction System for Beverage Can Manufacturing
  • Dust and Fume Extraction System for Leading Composite Manufacturer

    Case Study

    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
    View more: Dust and Fume Extraction System for Leading Composite Manufacturer
  • Bespoke solutions for beverage can manufacturer in UK

    Case Study

    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
    View more: Bespoke solutions for beverage can manufacturer in UK
  • Bespoke BlueClean® Dust Control with Additional HEPA Filtration

    Case Study

    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
    View more: Bespoke BlueClean® Dust Control with Additional HEPA Filtration
  • Leading Brick Manufacturer Dust Extraction​ System

    Case Study

    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
    View more: Leading Brick Manufacturer Dust Extraction​ System
  • Aluminium Scrap Extraction System for beverage can manufacturing plant

    Case Study

    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
    View more: Aluminium Scrap Extraction System for beverage can manufacturing plant
  • Dust extraction system at corrugated board facility

    Case Study

    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
    View more: Dust extraction system at corrugated board facility
  • Bespoke LEV system for dried herbs

    Case Study

    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
    View more: Bespoke LEV system for dried herbs
  • Turnkey dust extraction and filtration

    Case Study

    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
    View more: Turnkey dust extraction and filtration
  • Heat and Moisture Extraction for Corrugated Board Manufacturing at Ribble Packaging

    Case Study

    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
    View more: Heat and Moisture Extraction for Corrugated Board Manufacturing at Ribble Packaging
  • Wienerberger Clay Brick Production​

    Case Study

    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
    View more: Wienerberger Clay Brick Production​
  • Hot, Sprays and Cold Ducting System​

    Case Study

    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
    View more: Hot, Sprays and Cold Ducting System​
  • Scrap, Dust & Oil Mist Extraction in Salt Lake City

    Case Study

    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
    View more: Scrap, Dust & Oil Mist Extraction in Salt Lake City
  • Shell Press Extraction & Sweep Up Hopper System

    Case Study

    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
    View more: Shell Press Extraction & Sweep Up Hopper System
  • Skeleton and Slugs Extraction System

    Case Study

    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
    View more: Skeleton and Slugs Extraction System
  • Steel & Aluminium Trim Recycling System

    Case Study

    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
    View more: Steel & Aluminium Trim Recycling System
  • First Canning Plant in Kazakhstan

    Case Study

    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
    View more: First Canning Plant in Kazakhstan

  • 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
    View more: Operator Spot Cooling for Beverage Can Plant
  • Corrugated Trim Extraction at Nuttall Packaging

    Case Study

    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
    View more: Corrugated Trim Extraction at Nuttall Packaging

  • 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
    View more: Air System Modification Works for the Printing Industry