FEATURE Machine safety
FLEXIBLE FUME EXTRACTION
Arran Morgan, Product and Engineering Director at Donaldson BOFA, looks at the benefits of portable fume extraction, especially in Industry 4.0 environments, but says fixed systems still have their place in some applications
T
he traditional approach to fume extraction in manufacturing is to use a centralised/fixed or vent- to-air exhaust system. However,
Industry 4.0 demands greater flexibility and portable fume extraction supports more agile manufacturing approaches. Portable fume extraction is quick and easy to set up with minimal disruption, and it can be scaled progressively to meet demand. Alongside operational agility and efficiency benefits, this shift is also being driven by a growing focus on workplace atmosphere management and cost savings.
Flexibility advantages Portable systems are far more manoeuvrable than their fixed counterparts, providing flexibility that accommodates changes to the factory floor. Their ability to be quickly repositioned to support evolving layouts, without the need for major infrastructure changes, is a significant advantage in an Industry 4.0 environment.
The quick and flexible deployment of portable fume extraction systems may support low installation and maintenance costs. In contrast, a vent-to-air system requires a greater initial investment due to the need for a larger-scale, centralised infrastructure. This involves complex ducting and pipework, which not only adds to the initial cost but also makes future changes to the factory floor layout more expensive and time-consuming. Traditional vent-to-air systems expel both air and fumes outside, which can increase energy consumption as heated or cooled air must be continuously removed from the workplace. However, portable systems recirculate filtered air back into the workplace, which helps to retain heated air within the building and reduces the need for it to be replaced with cold outside air. Consequently, energy consumption for
12 June 2026 | Automation
space heating can be lower for portable fume extraction systems.
While portable systems offer flexibility, a fixed or centralised vent-to-air system might be better suited to certain applications. This includes large-scale industrial processes where centralised systems are designed to handle the emissions from multiple stations or processes, which can be more efficient for large installations. They are also central to the prevention of line contamination, as a centralised vent-to-air system removes airborne contaminants, reducing the risk of particles settling on production equipment, which could potentially damage product quality. Also, for high- volume and stationary process situations that are not expected to change, a fixed system can provide a robust and permanent solution to maintain consistent fume removal where there is no need for frequent repositioning. However, portable and fixed fume extraction solutions can be combined effectively to optimise production. For example, portable systems can be used to augment an existing vent-to-air (VTA) system, addressing specific processes or workstations that may not be a good fit for the main centralised exhaust. This dual functionality is particularly useful in agile manufacturing environments where a business might use a fixed VTA system as a base but also needs the flexibility of portable units. This allows businesses to adapt to changing production layouts and processes without incurring any significant costs and downtime associated with modifying
“ Portable
and fixed fume extraction solutions can be combined effectively to optimise production
”
a fixed, centralised infrastructure. This multi layered approach creates a more flexible and comprehensive fume extraction strategy in the factory environment.
Assessing the options Increasingly, portable fume extraction solutions are delivering enhanced support against the demands of Industry 4.0, through greater flexibility in an agile manufacturing setting. However, they can also be deployed to effectively support more traditional fixed fume extraction systems. Engineering and health and safety managers must therefore assess the appropriate options, ensuring they understand the potential risk any given process presents. They should also assess the installation and life cycle costs of fixed and portable systems, while projecting the future mix of work relative to agility, capability, and capacity. *This information is provided for general guidance only and should not be considered legal, regulatory, or technical advice.
Donaldson BOFA
www.donaldsonbofa.com
automationmagazine.co.uk
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