CP Hood had been appointed to complete the full fit-out of a new UK-based food manufacturing and processing facility. As part of this development, one of the key processes requiring specialist attention was the seasoning line, where various snack products are coated with fine flavouring powders. These powders are extremely lightweight and easily become airborne during production.
Airmatic was engaged to design and install a bespoke Local Exhaust Ventilation (LEV) system capable of controlling the dust generated at each stage of the seasoning process. Without effective extraction, fine seasoning dust was escaping into the general workspace, creating several concerns:
· Operator exposure: The airborne food dust was entering the breathing zone of workers, posing respiratory risks. Many food powders are classified as asthmagens, meaning they can trigger or worsen asthma when inhaled
· Explosion risk: Fine organic dusts, including food ingredients, can be highly explosive when dispersed into the air. Controlling and containing these materials at source is essential to prevent ignition or explosion hazards
· Regulatory compliance: Under HSE and COSHH regulations, employers must reduce exposure to hazardous substances to “as low as reasonably practicable” (ALARP). The existing environment did not meet these requirements without a properly engineered LEV system
· Hygiene and product integrity: Dust migration within a food manufacturing area can compromise cleanliness standards and increase the risk of cross-contamination
These combined challenges meant that CP Hood required not only an effective extraction solution, but one that was tailored to the specific behaviour of the seasoning powders, compliant with HSG258 guidelines and suitable for use within a high-hygiene food production environment.
Key Goals:
The solution and what we delivered:
To address the challenges posed by the seasoning line, Airmatic designed and installed a fully engineered, permanent LEV dust extraction system tailored specifically to the food processing environment. The solution centred around capturing airborne seasoning dust at the source and transporting it safely through a network of stainless steel, smooth-bore ducting. This ductwork ensures efficient airflow, prevents dust accumulation, and maintains the high hygiene standards required within food manufacturing.
The extracted air and entrained dust are conveyed to a reverse jet pulse cartridge filtration unit positioned outside the main building. This allows contaminants to be removed from the workplace entirely while keeping essential maintenance activity away from production areas. Food dust is not only an irritant, but often explosive, so the entire system was designed with a strong focus on operator protection and ATEX compliance. The dust collector was fitted with an explosion relief panel for controlled venting and an ATEX-certified non-return valve was installed within the duct system to prevent any explosion from travelling back toward the operators or production equipment. Additionally, the section of ductwork between the non-return valve and the dust collector was manufactured from heavy-duty, fully welded, flanged steel. This reinforced construction ensures the ductwork maintains its structural integrity even in the unlikely event of an explosion, adding a further layer of safety and reliability.
Behind the scenes, a significant amount of detailed engineering work was required to ensure the system would perform effectively once installed. Airmatic’s design team undertook rigorous calculations to confirm the correct duct velocities throughout the system, as both excessive and insufficient air speeds can lead to system failure, blockages, or dust settling. Pressure losses across the entire network were analysed to determine the appropriate fan size and performance requirements. Detailed mechanical drawings were produced, and several site visits were conducted to assess the environment, carry out clash detection, and refine installation methods to suit the building layout and production equipment.
Due to the nature of the project, CP Hood required specialist materials that are not widely available on short lead times. The ductwork needed to be manufactured from 316-grade stainless steel which is an essential choice for food industry compliance and corrosion resistance. To prevent delays and maintain the client’s project schedule, Airmatic utilised its in-house fabrication capabilities to manufacture every ducting component from scratch. This approach allowed full control over quality, accuracy, and hygiene considerations. In addition to the ductwork itself, Airmatic engineered a bespoke hygienic duct hanger system designed to avoid flat surfaces, crevices, or exposed threads, all of which can harbour germs or mould. This custom solution ensured that the installation would meet strict food industry hygiene and safety standards while remaining fully practical for long-term use.
Technical hurdles we faced and the solutions we provided:
Resolution: External ductwork was lagged to prevent condensation and all fabrication was completed in-house to meet lead times. The system was also commissioned and tested by Airmatic engineers, fully complying with HSG258 standards.
What long-term benefits can the client see:
How this project has impacted Airmatic: This project offered Airmatic a valuable opportunity to deepen its expertise in delivering complex LEV solutions within a highly regulated and hygiene-critical industry. Working with 316-grade stainless steel on such a large scale required the extraction and fabrication divisions to operate in exceptionally close alignment. This helped streamline internal communication processes, refine quality-control procedures, and enhance the coordination needed when dealing with specialist materials and bespoke components.
The project also reinforced the importance of early-stage planning, particularly around procurement, fabrication scheduling, and on-site sequencing. Managing a system that combined ATEX compliance, food-grade hygiene considerations, and extensive external ductwork pushed the team to elevate its project management approach. These lessons have since informed Airmatic’s methodology for future installations, ensuring greater efficiency, improved risk forecasting, and an even stronger capability to design and deliver customised solutions within tight client timelines.
Ongoing support for the client: Following the successful delivery of this LEV installation, CP Hood has continued to rely on Airmatic as a trusted partner for extraction solutions across their wider operations. The quality of the system, combined with Airmatic’s responsiveness and ability to meet challenging deadlines, has led to repeat work and ongoing collaboration. Additional projects are already in progress, further strengthening the long-term relationship and reinforcing the client’s confidence in Airmatic’s technical expertise and service.
Conclusion
This installation stands as a strong example of Airmatic’s ability to deliver safe, compliant and tailor-made LEV systems for challenging environments such as food processing. By combining engineering precision, in-house fabrication capability and a deep understanding of regulatory and hygiene requirements, Airmatic successfully provided a solution that protects operators, supports production efficiency, and ensures robust long-term compliance.