Dust Extraction and Fume Extraction specialists. Whether it's Downflow Booths, mobile filter units, or Hood Positioning Devices (Extraction Arms), flextraction have products to suit your dust and fume extraction requirements.

Derby College Apprentice & Welder Training Centre Equipped with new HPD Fume Extraction

Posted July 5th, 2010

What do you do with a derelict old engine shed that has Grade II listed status and had seen better days?  Derby College turned it into an Award winning 18,000m² flagship learning and teaching centre as part of a £48m regeneration scheme.

Opened in September 2009, the Roundhouse now offers students a wide range of courses including, art and design, building services, gas electric and plumbing as well as engineering and welding.

For the engineering and welding centre, Flextraction through their distributor, Leengate Industrial Welding Supplies Ltd from Nottingham, who were already suppliers of welding and fume extraction equipment to Derby College, were asked, after successfully tendering, to supply the fume extraction equipment for the new welding bays in the apprentice and welder training area.

Leengate supplied a Thermadyne Synergic Pulsed MIG 320A welding machine and a 200A AC/DC TIG welding machine for each of the 12 welding bays, but before welding could commence fume extraction equipment was required and it was here that Flextraction became involved.  Flextraction specifically designed and installed their latest HPD (Hood Positioning Device) system that was able to cater for the constricted space in the lower ground floor of the new Kirtley link building housing the welding shop and which also connects the old engine Roundhouse and the carriage repair shops.

Each welding bay has a self supporting 2m long, highly flexible articulated arm attached to a wall mounting bracket with each arm having an epoxy black 100mm diameter flared hood.  To discharge the fumes away from each bay, spiral galvanised sheet steel ducting was sized and proportioned to give a good conveying velocity through out it entire length.  The whole system was designed to go hand in hand with the structural set up of the building.  Access doors were also installed for inspection and servicing requirements.

A single 3-phase centrifugal, single inlet, medium pressure fan fitted with an impeller with backward facing blades supplies the conveying velocity operating at 2,895 revs/min.

Also included in the installation was a manual plasma cutting machine with a TEKA 600mm x 635mm air suction table to extract smoke and fumes using 160mm ducting under the bench at 1,500 m³/hr and a Grinding bench for weld preparation and finishing work was also supplied.

The complete fume extraction system was installed by Flextraction engineers.

James Thorneycroft, Engineering Lecturer at Derby College said: “Our new Roundhouse facilities allow us to offer students excellent welder and welding theory learning opportunities.  The HPD fume extraction system that we have installed provides our students with an excellent working environment.  The fact, that the equipment needs very little servicing, means that we can carry out apprentice and welder training without interruption.”

Minimising Flour and Ingredients Dust at Manchester Bakery Group

Posted May 25th, 2010

To control flour and ingredients dust at the point of weighing in preparation for onward baking, Martins Foods Group in Manchester has invested in two 4m downflow booths from Flextraction, designed to contain dust over large areas of emission.

Martins Food Group, one of Manchester’s longest established bakeries founded in 1922, has a modern 50,000ft² central bakery in Newton Heath producing and supplying over 150 bakery and sandwich products every day to the Group’s 28 retail outlets in the Manchester area.  The Group also has a 30,000ft² factory including a large holding freezer in Radcliffe, Manchester supplying frozen bakery products cakes and desserts to supermarkets and Foodservice outlets.

Flextraction’s own modular design, 304 stainless steel downflow booths with an acoustically enclosed fan to minimise overall noise level, operate on a re-circulatory airflow principle with a clean evenly distributed down flow of air at 0.5m/second. Extraction is via low level primary roughing filters and secondary bag filters and this then provides downflow via ceiling mounted 99.95% filtration efficient HEPA (High Efficiency Particle Arrestor) filters suppressing any dust downwards away from the operator’s breathing zone. Pressure indicating devices continually monitor the extraction performance, whilst automatically controlling the 2 x 2.2kW direct driven variable speed fans to maintain optimum operating conditions.

Louvered grilles in the lower rear wall capture the airborne contaminants. Because the booth operates using continuous re-circulation of the air within the booth, no airborne contaminates can escape into the external environment. Their modular designs allows a size to be manufactured to suit the application and they are found in a multitude of industries in addition to bakeries, these include dye and paint manufacturers as well as pharmaceutical and chemical manufacturers.

Neil Martin, Managing Director, Martins Foods Group said: “I first came across a Flextraction downflow booth during a visit to the Birds Bakery in Derby. I was impressed with the dust free conditions in the weighing area and although at the time we were already undertaking good practice to keep the dust levels as low as possible, I realised we could improve our own working environment to the betterment of our employees as well as the Company.

As a major bakery group in the Manchester area, we have to ensure that our operations meet with the most stringent health and safety standards and this investment has enhanced those standards.

After discussions with Flextraction, we decided in 2008, to invest in a 4m. booth, basically because it fitted into the size of our Newton Heath operations and once installed, we immediately saw environmental improvements. We made dust emission checks and found that the employees weighing up and tipping flour or ingredients into removable bowl mixers had the lowest emission levels of anywhere in the bakery, which was excellent. In early 2009 we decided to invest in another one for our Radcliffe operations with exactly the same results.

Both booths have been an excellent investment providing a much cleaner working environment and require very little maintenance, we only have to replace the easy to access filters, which is a very easy task.”

Fume Extraction does the job for Fluorocarbon

Posted May 19th, 2009

Teka Strongmaster

Fluorocarbon Bakeware Systems Ltd, Beeston, Nottinghamshire, one of Europe’s leading industrial bakeware product manufacturers recently installed two new welding cells complete with fume extraction equipment to enhance the capacity of their welding operations.

These new welding cells were installed by Engineering & Welding Supplies Ltd based in Sutton in Ashfield and distributors for Flextraction Ltd, who supplied two TEKA ‘Strongmaster’ BGIA approved 1,1 kW cartridge filter Local Exhaust Ventilation (LEV) units for the extraction of the welding fumes.

Fluorocarbon products include bread tin sets, large baking trays, pizza trays, pie hoops, cake tins and other baking products designed to meet individual customer requirements.  The company supplies many of the UK’s large plant and small size bakeries as well as exporting to a growing market in Europe.

To manufacture these products the company has extensive manufacturing facilities automated welding cells and stand alone MIG/TIG welding machines.

The TEKA ‘Strongmaster’ was chosen, because Lee Duckworth, Fluorocarbon’s Engineering Team Manager decided to incorporate portable extraction units to keep the footprint of the equipment in each cell to a minimum and at the same time the equipment should be adaptable for use in other processes if required and ‘Strongmaster’ fitted this specification.

‘Strongmaster’ is designed specifically for industrial fume extraction that is easy to use with a fan capacity of 3,000m³/hour, a separator and a durable manual dedustable large surface class W3 UPF filter cartridge, which remains in the unit during dedusting making operator exposure to dust extremely low.  The dust collecting bin has a volume of 50 litres and is sealed by a new TEKA developed sealing face lifter.  In addition a visual and acoustics filter monitor informs the operator when dedusting is required.

Lee Duckworth said: “We already had 5 existing welding cells, but because of strong demand for our products and the consolidation of an acquired competitor at Beeston, we needed to increase the capacity of our welding operations.  The new cells are being used to produce ‘fabricated bread straps’, which are seam welded bread pans held together by a strapping system and other parts depending on the construction.  Each cell is flexible enough to cope not only with different design parts, but also materials ranging from 0.9mm – 2mm thick alusteel and aluminium. The introduction of these cells has resulted in improved product quality, greater reliability and higher output.”

Each of the two new welding cells comprises a Lorch S-series Saprom digital MIG/MAG twin pulse inverter based welding machine and a Strongmaster fume extraction filter.  Each welding machine was adapted to be used with a Mitsubishi linear actuator mounted in a framework with viewing windows.  All controls are managed by a manually operated control pendant which allows manipulation of the PLC to change welding parameters including weld bead length, weld speeds as well as change welding programs stored in the welding machine.

Lee Duckworth continued: “Each cell is manually loaded and unloaded.  We have seen re-work levels improve with improved product quality, whilst the flextraction equipment has much improved the working environment for the operators.  The operators clean the filters each week, which is very easy to do.  We have also undertaken air sample monitoring and this has shown a tremendous improvement in air quality.  In the past although fume levels were not harmful they were unpleasant and our operators had to wear masks.  To-day, the efficiency of the fume extraction equipment and the resultant air quality means this is not necessary.”

Ian Elliott of Engineering & Welding Supplies said: “Working closely with Fluorocarbon and flextraction’s installation engineers, we were able to ensure that we were able to install the fume extraction equipment on the mounting flange and sort out the power requirement.  It is essential that the correctly specified fume extraction equipment in used in any welding application for the amount of cubed area you are extracting from.  Flextraction took care of all these requirements for us and made the installation very efficient with the customer more than satisfied at the end of the day.”

Extraction Equipment Eliminates Fume Emissions in Extrusion Process

Posted October 17th, 2008

When Polyplas Extrusions Ltd, in Stourport on Severn, received a large order to supply profiled sections to a UK customer, they turned to Flextraction.

Polyplas’s order called for profiled sections made from Santoprene™ brand thermoplastic vulcanizates (TPV), which comprises  of high-performance elastomers, combining the desirable characteristics of vulcanized rubber, such as flexibility and low compression set, with the processing ease and re-cyclability of thermoplastics.  Polyplas found, when extruded over extended periods, this material produced fumes in the production area to such an extent that fume extraction equipment was required.

Polyplas is a manufacturer of custom made thermoplastic profile extrusions with a new 18,500m² factory operating six extrusion lines, two of which are coupled with jockey extruders to produce co-extruded profiles, as well as ancillary equipment for additional processing.  Established 20 years ago, they supply both UK and Export markets with products for building &construction, bathroom & shower manufacturers, transport & marine, medical as well as mechanical / industrial engineering.

Although not all the lines are being used on this particular contract, a strategic decision was made to provide fume extraction on all six lines as this would cover all future eventualities.  Flextraction was chosen to supply 6 x 1.5m long, 150mm diameter ‘Flextractor’ articulated arms each with an epoxy black painted flared hood, all connected to a Sodeca 3 phase 230/240V 50Kz 2.2kW centrifugal fan running at 2,600rpm with a maximum airflow of 7,800m/hr, more than enough to handle the 5,100m³/hr air volume required to cover all six lines.

The spiral galvanised steel ducting system to take the fumes away from the work place to an outside discharge flue and cowl, was designed by Flextraction to provide the correct conveying velocity throughout its length with the necessary access and inspection doors for easy maintenance.

Clive Chappel, Works Manager at Polyplas commented: “Although current environmental legislation played little part in our decision to purchase this equipment, we were fully aware that the installation of fume extraction equipment would help the working environment for our line operators.  Using the internet and my own knowledge of fume extraction we sought out suppliers.  Flextraction was chosen because their equipment was right for the job.  Although the installation is still new, we have found that it meets our requirements, with our line operators finding the articulated arms easy to use.  We decided to undertake the installation during our shut down period, but to meet orders we had to operate all the lines.  This, however, caused no problems and the installation proceeded without a hitch.”

Fume & Dust Extraction Systems at Unistrut Ltd

Posted April 29th, 2008

When Unistrut Ltd made the decision to relocate their manufacturing, warehousing and distribution to one central location within the West Midlands by moving from Oldbury to West Bromwich, about 2.5 miles away, they turned to Flextraction to help them dismantle, re-install and upgrade their existing fume and dust extraction systems.Unistrut supplies metal framing, cable management and pipe support products to the electrical, mechanical and industrial services industries throughout the EMEA region (Europe, Middle East & Africa). Significant projects include cable trays to the new Terminal 5 at Heathrow and channels to the £75 million refurbishment of the M25 Holmesdale tunnel. The Company forms part of the Tyco Electrical & Metal Products business division.

Some of the extraction systems at Oldbury were relatively new and others were in good condition, so Unistrut decided not to buy complete new systems, but to utilise their existing system. Following a number of meetings with Flextraction, they contracted them to carry out the dismantling, undertake any needed refurbishment, install new equipment where required and re-locate it all to West Bromwich. Flextraction were happy to work to a timetable decided upon by Unistrut Maintenance Engineers, although these timetables were often revised at short notice, the re-location took just 4 weeks to complete.

Eric Shropshall, Unistrut’s Production Engineer said: “The complete fabrication shop was moved including a robot welding cell, continuous MIG seam welding machine, MIG welding benches plus 2 cable ladder MIG welding benches all of which required fume and dust extraction systems. All this equipment is used to weld carbon and stainless steel bracket assemblies for our Metal Framing Systems including cantilever brackets. We also weld cable ladders in widths from 150mm to 900mm and depths from 100mm to 150mm, with all their necessary accessories to provide safe and effective management of heavy duty electrical cabling.”

Lee Darton, Flextraction’s Sales Manager said: “Our distributor in the West Midlands, Central Welding Supplies Ltd was fully involved in obtaining this contract, but overall we were responsible for carrying out the project. In addition to the re-location we manufactured and supplied a new extraction system for 2 cable ladder welding jigs using lip extraction, which uses long extraction manifolds mounted under the welding area to extract the welding fumes downwards away from the welder’s face. This was a new concept for Unistrut and has resulted in a cleaner working atmosphere.”

Eric Shropshall continued: “In addition to the ladder jig extraction and refurbishment of some of our equipment, Flextraction installed new more efficient fans to aid extraction. We currently discharge our welding fumes into the outside atmosphere, but we are currently working to use filtered units, which will allow us to re-circulate clean air back into the workshop and reduce our heating costs. The only problems we encountered were difficulties supporting the 8 ductwork stacks on the side of our building, fortunately Flextraction came up with a solution using some of our own products to construct framework to support the structures and spread the loads. We have been impressed by the service from Flextraction and their ability to react quickly to our requirements and find solutions to any problems we incurred. The result is that our fabrication shop has a better working environment.”

Flextraction Helps Working Environment At Foundry

Posted October 12th, 2007

When Flextraction installed a lead/copper dust and fumes extraction system at Daido Industrial Bearings Europe Ltd in December 2006, it enabled them to meet the requirements of their local authority environmental department and receive their pollution prevention and control (PPC) permit.

Daido, in Ilminster, Somerset produces plain bearings, bushings and thrust bearings for medium speed diesel engines, turbochargers and a range of other rotating and reciprocating machines for the engineering, shipbuilding and power generation sectors of industry. The Flextraction extraction system is being used in the production of castings for bearing casings on Dross Tanks, Crucibles and cooling stations. In total there are 9 extraction points with various hoods, including fishtail hoods and billet hoods.

The complete system comprises 1.5m diameter galvanised mild steel ductwork with radius bends, a Kiekens 12-FTEN-500/0.9, centrifugal, 400V 30kW, IP55 classification fan/air mover with a maximum air extraction rate of 18,200 m³/hr extracting from all the extraction points at the same time, a Donaldson Torit primary cartridge filter/air cleaner with 24 ultra web flame retardant filter cartridges, having reverse jet air filter cleaning, automatic flame retardant filters and 423.6m² filter area with a filtration velocity of 0.72m/min.

There are also 6 x 32m², HEPA, EU 13, 370Pa gauge secondary filters in line with a magnehelic monitoring gauge. The expected lifetime of these filters is around 2 years.

Alan Riste, Daido’s Health and Safety Co-ordinator said: “Previously we used a 24-inch square ductwork system with inline fans extracting the contaminants into the atmosphere and it became clear we needed a new system primarily to meet the environmental standards for our 600mm diameter high cover stack system with a jet cowl. Also the air flows of the old system, needed to be continually maintained to control the hazard of lead to the operators.

The project began 9 months prior to the installation in December 2006; Flextraction undertook an initial survey of our requirements and came up with a solution that both met our requirements in the quality of the equipment as well as our requirement to control the lead emissions to the atmosphere.

Since the system was installed our last round of personal air monitoring in the area of the system has seen our lowest levels of lead, with improvements both on health and safety as well as for the local environment. We work day and night shifts so it is in constant use and has been very easy to maintain with the filters meeting our expectations and requirements.”