Multi-Zone Hot Duct with Dust and Fume Extraction

Coordinated Retrofitting for a Live Facility

The project required rigorous planning to adhere to strict production schedules and facilitate the retrofit of complex systems with minimal downtime. All works needed to be carried out without compromising compliance with stringent safety, environmental, and regulatory standards. Despite these constraints, integratedAIR delivered each phase of the installation without disrupting ongoing operations.

Three-Phase Project Breakdown

The project was strategically divided into three phases, which were completed over 12 months, to address specific functional requirements while ensuring continuity of production. As part of the overall works, integratedAIR also completed a fume enhancement extraction system installation, finalised the high-temperature hot ductwork, and successfully repositioned the filtration units. These implementations were coordinated in conjunction with our partner DURR as the Main RTO was installed.

PHASE 1

LSL Area Fume Extraction Enhancement System

The project began with the installation of an LSM area fume enhancement System. These emissions were directed to a new BlueClean VT filter unit. This was made ready to send filtered air onwards to the air concentrator that would be installed in the next phase.

PHASE 2

Hot Duct System

The second phase focused on the high-temperature extraction line. A new hot duct extension was installed, and the primary hot ductwork was manufactured in-house at fabriSYS, ensuring full quality control.

This phase also incorporated NFPA 68-compliant safety features, including explosion relief panels, access doors for internal cleaning, and door sensors. The system was extended with additional cold ducting to capture ink mist and over-varnish emissions, to enhance air quality across the facility.

PHASE 3

Filter Relocation

The final phase involved relocating two existing BlueClean VT Reverse Jet Dust Filters that Integrated Air installed in 2016, to a new position that aligned with the new RTO position and Cold Air Concentrator. These changes kept the system compliant while boosting long-term maintainability.

High Temp Ductwork

For the highest-temperature areas of the ducting system, which operate at a maximum of 250°C, integratedAIR installed 100 mm-thick wired mattress insulation. This mineral wool-based material is designed to perform in sustained high-heat environments, maintaining thermal stability while resisting shrinkage and degradation over time. This insulation was securely fixed and further clad with plain aluminium sheeting, fastened with pop rivets to provide durability and resistance to external elements.

Crucially, integratedAIR delivered a fully integrated, multi-zone extraction system across three active production windows, all while maintaining zero production downtime during installation. The solutions meet stringent standards and comply with site-specific requirements, delivering significant improvements in air quality and maintenance access.

Why Choose integratedAIR?

The success of this Abatement project demonstrates why multiple global can makers are continuing to turn to DURR and IntegratedAIR’s partnership for the industry's best Thermal Oxidiser solutions.

At integratedAIR Systems, we deliver intelligent, tailored solutions for abatement and thermal management and ductwork insulation carefully designed to match your process needs. Contact our experts to discuss how we can support your next project.