Client Overview
A precision manufacturing company based in Ilkeston, Derbyshire, operating injection moulding processes for specialist thermoplastic components. As part of their commitment to maintaining a safe working environment and meeting COSHH requirements, the company identified the need for effective fume extraction at one of its injection moulding machines.
The Challenge
During the injection moulding process, fumes were being generated from a BOY XVS injection moulding machine using Pyrogaurd thermoplastic materials. To ensure operator safety and compliance with workplace exposure regulations, the customer required a dedicated Local Exhaust Ventilation (LEV) system capable of capturing airborne contaminants at source before they could enter the working environment.
The solution needed to:
- Effectively extract fumes from the machine enclosure.
- Minimise disruption to production and maintenance activities.
- Meet HSE guidance and LEV best practice standards.
- Provide a reliable, easy-to-maintain system for long-term operation.
Our Solution
Impact Air Systems designed and installed a dedicated LEV system specifically engineered for the injection moulding process.
The solution included:
- A purpose-designed extraction system capable of extracting approximately 900m³/hr of contaminated air from the rear of the machine enclosure.
- A 0.55kW inline fan connected to a smooth-bore galvanised ductwork system to maximise airflow efficiency.
- Removable tension-clip duct sections, allowing operators easy access to the rear of the machine for maintenance without compromising system performance.
- High-level discharge through the external wall, terminating above roof level via a high-velocity cowl to ensure safe dispersion of extracted fumes.
- Airflow monitoring to provide operators with a simple visual indication that the system is functioning correctly.
- Full commissioning, operator training, and provision of an LEV logbook and user manual.
- The system was designed in accordance with HSG258 guidance, ensuring compliance with recognised LEV standards and best practices.
The Results
The completed LEV installation provided the customer with a dedicated fume extraction solution tailored to their injection moulding process.
Key benefits included:
- Improved capture and control of process-generated fumes at source.
- Enhanced protection for machine operators and surrounding personnel.
- Compliance with HSE LEV guidance and support for COSHH obligations.
- Simplified maintenance access through the removable ductwork design.
- Increased confidence in ongoing system performance through airflow monitoring and commissioning verification.
The result is a safer and more controlled manufacturing environment, helping maintain operational efficiency while prioritising workplace health and safety.
In need of a fume extraction system? Get in touch with our expert team to discuss your operational requirements.