Bespoke LEV Systems Designed Around Your Workplace
An effective Local Exhaust Ventilation (LEV) system starts with understanding how contaminants are generated, released and captured within the workplace, including their properties, toxicity and hazard banding. RB Industrial designs, manufactures, installs and commissions bespoke LEV systems for dust, fume, vapour, oil mist and other airborne contaminants across industrial and commercial environments.
From a single extraction point or specialist capture hood to complex multi-branch systems serving an entire production facility, our engineers design extraction around the process, airflow requirements, filtration, workplace layout and operational needs.
RB can also integrate ATEX and DSEAR requirements, electrical controls and automation into the overall system design where required.
Why Good LEV Design Matters
LEV needs to control contaminants at source, before they enter the operator’s breathing zone. The effectiveness of the finished system depends on much more than the size of the fan or filter.
The contaminant, process, capture arrangement, hood design, required airflow, ductwork configuration, filtration and workplace conditions all need to be considered together. Poorly positioned capture points, insufficient airflow, excessive pressure losses or inappropriate filtration can result in poor contaminant capture, increased exposure and unnecessary energy consumption.
Our design process begins with understanding the application. We assess the source and characteristics of the contaminant, how the process operates, employee interaction, existing ventilation and extraction, available space and future requirements before developing the system specification.
For combustible or flammable dusts and substances, the design may also need to consider DSEAR, hazardous area classification (HAC), ATEX requirements and potential ignition sources.
LEV Systems for Different Applications
RB Industrial designs and installs LEV systems for a wide range of processes and contaminants, including, but certainly not limited to:
| Application | Typical Extraction Requirements |
|---|---|
| Woodworking | Wood dust extraction, machine capture, filtration and return-air considerations |
| Metalworking & fabrication | Welding fume, grinding dust, oil mist and process extraction |
| Food & ingredient processing | Flour and food dust extraction, filtration and hygienic capture |
| Automotive | Vehicle exhaust extraction, welding fume and workshop ventilation |
| Paint spraying | Spray booth extraction, filtration and clearance-time requirements |
| Chemical & laboratory | Hazardous vapours, gases, fume cupboards and specialist extraction |
| Manufacturing & process industries | Dust, fumes, vapours, oil mist and process emissions |
| Recycling & waste | Dust, particulates, odours and process extraction |
| Combustible dust processes | ATEX/DSEAR considerations, hazardous area classification and specialist filtration |
Engineering-Led LEV System Design
Our engineers consider the complete air movement system, from the point where the contaminant is generated through to filtration, discharge and energy costs.
Capture & Hood Design
Capture hoods, enclosures, downdraught benches and extraction arms are designed around the process and operator interaction. The objective is to capture contaminants effectively at source while providing sufficient airflow without unnecessarily increasing energy consumption. Hood geometry, capture distance and velocity are considered alongside the way the contaminant is released and how the operator interacts with the process.
Hazard Banding.
By identifying the exposure potential and comparing it with the relevant hazard band, the appropriate level of control can be determined and the most suitable LEV approach identified. Our designers consider the properties of the hazardous substance in all relevant states, including solid, dust, mist, vapour and gas, together with how the process and source behave. This informs the specification of appropriate hood design, capture velocities, controls and materials.
Systems can range from single-point extraction through to complex centralised installations serving multiple machines or processes.
 Airflow & Ductwork
We calculate the required airflow and capture and transport velocities for the application, then design ductwork to provide the required performance across the system.
For multi-branch systems, this includes consideration of branch airflow, system resistance, pressure losses and airflow balancing so that individual extraction points receive the required performance. Airflow indicators and monitoring can also be incorporated where appropriate to provide ongoing confirmation that the system is operating as intended; also refer to SmartAIR control.
Ductwork can be designed and manufactured in-house, including square and round ducting, transitions, branches, large-radius bends and specialist fabricated components.
Fans & Filtration
Fan and filtration equipment is selected according to the contaminant, required airflow, system resistance and operating conditions.
Depending on the application, systems may incorporate bag or cartridge filtration, cyclones, wet or dry scrubbers, electrostatic precipitators and specialist filter media.
Energy-efficient fans, inverters and automated airflow control can also be incorporated to match extraction performance to the process and reduce unnecessary energy consumption.
To maximise energy savings and ensure exposure control is consistent and maintained, the fully automated SmartAIR system would be recommended; Payback can be less than 1 year and offers many advantages; see below
ATEX, DSEAR & Specialist Extraction
Where systems handle combustible dusts, flammable gases, vapours or mists, the extraction design may need to take account of DSEAR and hazardous area classification.
RB can incorporate these requirements into the design, including consideration of:
- Hazardous Area Classification and zoning
- ATEX equipment selection
- Airflow requirements within hazardous areas
- Conductive or antistatic filter media
- Earth bonding of ductwork and equipment
- Ignition source control
- Airflow alarms and monitoring
- Duty/standby extraction arrangements
- Appropriate control and shutdown systems
For laboratory and other processes involving flammable solvents, gases or powders, the extent of hazardous areas can also be influenced by the effectiveness of ventilation and extraction, making airflow performance and appropriate monitoring important considerations.
RB’s DSEAR/ATEX specialists work alongside the LEV engineering team to ensure these requirements are considered as part of the overall system design.
Intelligent Airflow Control; SmartAIR
Exposure control is becoming more crucial to save lives and reduce occupational diseases. The HSE are now more vigorous than ever enforcing this under the COSHH regulations.
SmartAIR has been developed to provide a number of primary benefits for Industrial ventilation (LEV) systems
- Ensures exposure control is consistent and maintained throughout the LEV system life, with real-time warnings available to operators & managers of any system / exposure issues. Local indicators/ display modules (LDM) provide crucial alarms & info for each station / machine. A comprehensive web-app for managers / external staff is provided, within the standard product. The System can be expanded into a full Health & Safety & Environmental Monitoring system if required.
- Complete System automation, via a distributed system architecture; including system airflow measurement & control / balancing on all branches (no balancing dampers required). Branch dampers can be automated to machine operation, operator locations (PIR) etc. The system always remains in-balance and optimised, whatever the operational operating scenario. Filter life can be extended dramatically and compressed usage reduced substantially.
- Unique Dust Deposition Sensing System, ensuring no product drop out (in header duct), especially during low utilisation periods; this can provide substantial energy savings.
- A wireless, self powered damper control system; enabling easy installation and adaption as changes are made. Autonomous Airflow Controllers (AAC’s) can be specified, where the energy is provided with ‘micro’ energy harvesters, drastically reducing installation time & costs with little or no wiring.
- Where required, the system is fully ATEX certified (dusts & gases) including the dampers, venturi airflow meters, LDM, AAC’s, dust deposition system DDS.
- The combined result provides the most efficient and compliant LEV / Industrial ventilation system on the market, maximising energy savings more than any other system. Payback can be less than 1 year on larger systems.
- The system can be expanded / adapted to include a wide range of applications
- Laboratory fume cupboard control; Variable air volume VAV & Constant Volume CVD control
- Woodworking applications, controlling regen fans, rotary valves, screw conveyors, pneumatic conveying systems
- Centralised vacuumation system control
- A whole host of sensors including Bin level, temperature, humidity, CO2, particulate matter (PM), Filter / stack emissions monitoring etc.
With the emphasis on exposure control and energy savings even a 1 or 2 branch system can benefit and be cost effective with our distributed control and modular architecture
Design, Manufacture, Installation & Commissioning
RB provides a complete LEV service rather than supplying equipment in isolation.
Survey & Specification
We assess the workplace, processes, contaminants and existing systems to establish the requirements.
System Design
Our engineers develop the extraction, ductwork, filtration, fan, control and capture arrangements around the application.
Fabrication & Manufacture
Ductwork and fabricated components can be manufactured in-house, allowing the system to be built around the specific requirements of the application and installation environment.
Installation
Our installation team installs the complete system, including extraction equipment, ductwork, controls and associated components.
Commissioning & Balancing
Airflows, pressures and system performance are checked against the design requirements, and the system is balanced where necessary. Commissioning includes installation checks, system balancing and performance checks, assessment of control effectiveness and reporting.
Where an existing LEV system has limited or no original documentation, performance data can be measured and recorded to establish whether the system is providing effective control.
Following commissioning, RB can provide ongoing LEV testing, servicing and maintenance to help maintain system performance.
Why Choose RB Industrial?
RB combines LEV engineering, occupational hygiene, fabrication, electrical control, filtration and ATEX/DSEAR expertise to deliver complete extraction systems rather than treating each element in isolation.
From a single extraction point through to complex multi-branch systems, our approach considers the process, contaminant, workplace and people using the system.
We can support projects from initial assessment and design through to manufacture, installation, commissioning and ongoing LEV testing and maintenance.