Heavy-Duty LEV System with Reinforced Fume Extraction Arms for Polymer Plants
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The Challenge: Preventing LEV Component Failure in Odour-Heavy Environments
A polyurethane and polymer production facility required a comprehensive Local Exhaust Ventilation (LEV) system to manage both airborne dust and strong chemical odours across 12 high-activity workstations. A common failure point in industrial air filtration is the “collapse” of conventional, flexible suction arms due to heavy usage and mechanical fatigue. The plant needed a “non-collapse” solution that provided both 360-degree flexibility and industrial-grade durability.
A polyurethane and polymer production facility required a comprehensive Local Exhaust Ventilation (LEV) system to manage both airborne dust and strong chemical odours across 12 high-activity workstations. A common failure point in industrial air filtration is the “collapse” of conventional, flexible suction arms due to heavy usage and mechanical fatigue. The plant needed a “non-collapse” solution that provided both 360-degree flexibility and industrial-grade durability.
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The Solution: Reinforced Multi-Point Fume Extraction with Carbon Filtration
We engineered and installed a centralised odour and dust extraction system featuring a high-durability ducting network:
We engineered and installed a centralised odour and dust extraction system featuring a high-durability ducting network:
- “Non-Collapse” Bespoke Suction Arms: To solve the issue of sagging or failing arms, we developed a reinforced solution using “lipped” galvanized piping. These rigid segments rotate smoothly around each other using integrated industrial bearings, ensuring the arms remain exactly where the operator positions them without losing suction or structural integrity.
- Dual-Stage Air Purification: The 12 extraction points feed into a centralised filtration unit. This includes a high-surface-area cartridge filter for dust particles, followed by an active carbon filter (carbon scrubber) to neutralise volatile organic compounds (VOCs) and polymer odours.
- High-Volume Airflow: Powered by a heavy-duty industrial fan, the system ensures consistent negative pressure at every hood, maintaining a safe, HSE-compliant working environment.
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The Result: Reliable, Maintenance-Free Odour Control
The bespoke bearing-assisted extraction arms have eliminated the downtime caused by failing flexible hoses. By combining high-efficiency dust capture with chemical odour neutralisation, the facility has achieved superior air quality and full compliance with UK workplace safety standards.
The bespoke bearing-assisted extraction arms have eliminated the downtime caused by failing flexible hoses. By combining high-efficiency dust capture with chemical odour neutralisation, the facility has achieved superior air quality and full compliance with UK workplace safety standards.
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Fume Extraction Arms – Technical Specifications Table
| Specification | Technical Details |
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| System Type | Centralised LEV (Local Exhaust Ventilation) |
| Extraction Points | 12 Bespoke Suction Points |
| Arm Design | Reinforced Bearing-Assisted Rigid Arms |
| Filtration Stage 1 | Central Cartridge Filter (Dust Capture) |
| Filtration Stage 2 | Active Carbon Filter (Odour/VOC Removal) |
| Ducting Material | Galvanized Steel with Lipped Ends |
| Application | Polyurethane & Polymer Production |
| Key Advantage | “Non-collapse” arm design with 360° rotation |
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Integrated Air Quality & Filter Performance Monitoring
To ensure the Local Exhaust Ventilation (LEV) system operates at peak efficiency, we offer integrated monitoring solutions that provide real-time data on both system health and workplace safety:
- VOC & Odour Sensing: For polymer and polyurethane plants, we can integrate Photoionisation Detectors (PID). These sensors monitor the output of the Active Carbon Filter, providing an automated alert when the carbon is saturated and needs replacement—preventing chemical breakthrough and ensuring constant odour control.
- Differential Pressure Monitoring: To protect the cartridge filters, we install digital manometers that measure the pressure drop across the filter media. This allows for “predictive maintenance,” signaling the exact time for a pulse-clean or filter swap before suction at the fume extraction arms is compromised.
- Airflow Velocity Tracking: Hand-held or fixed anemometers ensure the system maintains the 15-20 m/s transport velocity required by UK health and safety standards to prevent dust from settling within the galvanized ducting.