Why Air Quality Matters in Food & Beverage Production
In the food and beverage industry, maintaining clean, contaminant-free air isn’t just about comfort — it’s a vital part of ensuring product safety, regulatory compliance, and efficient production. From flour and sugar dust in bakeries to fumes from cooking oils or packaging processes, airborne contaminants can quickly compromise hygiene, equipment, and employee health.
An effective dust and fume extraction system plays a crucial role in controlling these risks. It captures pollutants at the source, filters them efficiently, and ensures the workspace meets COSHH, HSE, and ATEX safety standards. The result? A cleaner, safer, and more productive facility.
At Western Air Ducts, we specialise in designing, installing, and maintaining bespoke extraction systems for the food and beverage sector — helping manufacturers across the UK achieve reliable air quality and full regulatory compliance.
Understanding the Unique Air Challenges in Food & Beverage Plants
Food and beverage manufacturing environments present some of the most complex air quality challenges in any industry. The combination of fine powders, heat, oils, and cleaning chemicals means that airborne particles and fumes are constantly being generated during production.
Common Dust Sources:
Ingredients such as flour, sugar, starch, milk powder, cocoa, and spices produce fine dust that easily becomes airborne. Over time, these particles can settle on equipment, packaging lines, and finished products — posing serious hygiene and contamination risks.
Common Fume Sources:
Processes like baking, frying, roasting, or sealing create vapours, steam, and chemical fumes that can affect air quality and worker comfort. In some cases, these emissions may even contain allergens or hazardous compounds.
Safety and Compliance Concerns:
Uncontrolled dust isn’t just a cleanliness issue — it’s a safety hazard. Fine organic dust, such as flour or sugar, can be combustible, increasing the risk of fire or explosion under the ATEX directive. Additionally, prolonged exposure to airborne dust and fumes can lead to respiratory issues among staff and potential COSHH compliance failures.
To address these challenges, food and beverage facilities must use specialised dust and fume extraction systems designed to capture and filter airborne contaminants efficiently while maintaining hygiene and safety across all production areas.
Key Factors to Consider When Choosing an Extraction System
Selecting the right dust and fume extraction system for a food or beverage plant requires careful evaluation. Every facility has unique production processes, ingredients, and hygiene requirements — meaning a one-size-fits-all approach rarely works. Below are the key factors to consider before investing in an extraction solution.
- Type of Contaminant
The first step is identifying the main type of pollutant — whether it’s dust, fumes, or a mix of both. For instance, bakeries typically face fine flour dust, while packaging lines or frying operations may produce oily vapours or fumes. The system’s design and filtration stages should be tailored to capture these specific contaminants effectively. - Airflow and System Capacity
Airflow determines how efficiently the extraction system captures and removes airborne particles. Undersized systems won’t provide adequate suction, while oversized systems waste energy. A proper LEV (Local Exhaust Ventilation) design ensures balanced airflow, optimised ducting, and minimal energy loss. - Filtration Efficiency and Hygiene Standards
In food environments, air purity is directly linked to product safety. Choose extraction units with HEPA or multi-stage filters to remove even microscopic particles. Smooth internal surfaces and easy-clean ductwork are also essential to prevent contamination build-up. - Compliance with Regulations
All extraction systems must meet COSHH, HSE (HSG258), and, where relevant, ATEX requirements. A compliant system protects your business from costly fines while keeping employees safe from harmful exposure. - Maintenance and Accessibility
Hygiene-focused industries demand systems that are simple to clean and maintain. Quick-access filter housings, removable ducts, and tool-free maintenance can save hours of downtime and reduce contamination risk. - Noise and Energy Efficiency
Production areas operate for long hours — so low-noise, energy-efficient fans and motors are vital. Modern systems can include energy-saving controls that adjust performance automatically based on process demand.
By evaluating these factors early in the design process, food and beverage manufacturers can ensure their system is both technically effective and legally compliant — providing long-term protection for products, staff, and equipment.
Common Extraction System Types for Food & Beverage Plants
Every food and beverage facility has its own air quality challenges — from airborne flour dust in bakeries to chemical fumes in packaging areas. Choosing the right extraction setup depends on the size of the facility, the type of process, and the level of control needed. Below are some of the most effective system types used across the industry.
- Centralised Dust Extraction Systems
Ideal for large-scale food production sites, centralised systems connect multiple extraction points to a single filtration unit. They provide consistent suction power across several work areas, making them perfect for operations such as ingredient mixing, weighing, and product transfer. Centralised systems also simplify maintenance and ensure uniform air quality throughout the facility. - Local Exhaust Ventilation (LEV) Systems
LEV systems capture airborne contaminants directly at the source — before they can spread through the workspace. This setup is common in areas with high dust generation or where fumes are released during heating, sealing, or cooking processes. A well-designed LEV system ensures maximum efficiency with minimal airflow loss, keeping exposure levels within COSHH limits. - Fume Extraction Arms
For processes like heat sealing, roasting, or cleaning with volatile chemicals, flexible fume extraction arms are an excellent choice. These can be easily positioned near emission points, providing targeted removal of fumes and vapours. They are especially useful in packaging or maintenance zones where fixed ducting isn’t practical. - Portable Extraction Units
In smaller food facilities or where operations frequently change, portable extraction units offer flexibility without permanent installation. These self-contained systems are easy to move, quick to set up, and ideal for temporary production lines or short-term operations. - Hybrid Systems
Some plants benefit from combining fixed LEV systems with mobile extraction units — offering both efficiency and adaptability. This hybrid approach allows for optimal control of airborne contaminants across various stages of production.
At Western Air Ducts, we design, install, and maintain all of these systems, ensuring each solution is tailored to your facility’s specific needs. Whether you require a full centralised system or a small, localised setup, our engineers deliver reliable performance and full regulatory compliance.
Hygiene, Safety & Compliance: What the Law Requires
In food and beverage manufacturing, air quality management isn’t optional — it’s a legal and regulatory necessity. The UK has strict guidelines to ensure that dust and fume emissions do not compromise food safety or worker health. Understanding and meeting these standards is key to avoiding costly penalties and maintaining a safe, compliant workspace.
- COSHH Regulations (Control of Substances Hazardous to Health)
The COSHH Regulations require employers to control substances that can harm employees’ health. Dusts and fumes produced during food processing — such as flour, sugar, or cleaning chemicals — fall under this category. A properly designed LEV (Local Exhaust Ventilation) system helps meet these obligations by capturing contaminants before they enter the breathing zone. - HSE Guidance: HSG258
The Health and Safety Executive (HSE) publication HSG258 – Controlling Airborne Contaminants at Work provides detailed guidance on the design, use, and testing of LEV systems. Following these best practices ensures your extraction equipment operates safely and efficiently, protecting both staff and production environments. - ATEX Compliance
For facilities handling combustible ingredients like flour, starch, or sugar, ATEX certification is crucial. It ensures all components of your extraction system — from fans to filters — are explosion-proof and meet the required European safety standards. This helps prevent fires and explosions caused by airborne dust ignition. - LEV Testing and Documentation
According to HSE regulations, all LEV systems must be tested at least every 14 months to verify their performance. This testing ensures that the system continues to control contaminants effectively and remains compliant with COSHH and HSG258. Proper documentation and test reports are essential for audits and inspections.
At Western Air Ducts, we don’t just design and install compliant systems — we also provide comprehensive LEV testing, inspection, and maintenance services. Our engineers ensure that your air extraction system operates safely, meets legal requirements, and maintains peak performance year-round.
Custom Design: Why Every Food Facility Needs a Tailored Solution
No two food and beverage facilities are exactly the same — each has unique processes, layouts, and hygiene requirements. That’s why a custom-designed dust and fume extraction system is essential for achieving reliable performance and full compliance.
A tailored system takes into account:
- Production layout and workflow: Understanding how ingredients move through the plant helps position extraction points strategically.
- Type of materials handled: Dust from flour or sugar requires different filtration technology than fumes from oils or packaging lines.
- Process scale and air volume: System capacity must match production output to ensure efficient contaminant removal.
- Cleaning and hygiene standards: Ducting, filters, and enclosures should be designed for easy access and regular washdowns without contamination risk.
At Western Air Ducts, we start with a detailed on-site survey to assess your specific air quality challenges. Our engineers then create a 3D system design, ensuring optimal airflow, minimal energy consumption, and seamless integration with your existing infrastructure.
We also handle every stage of the process — from installation and commissioning to ongoing maintenance and LEV testing — providing a complete turnkey service. With decades of experience across food manufacturing environments, our team ensures that every system not only meets regulations but enhances operational efficiency and product quality.
A well-designed extraction system isn’t just an investment in compliance — it’s an investment in cleaner production, safer workplaces, and long-term performance.
Maintenance & Testing: Keeping Your System Efficient
Once your dust and fume extraction system is installed, proper maintenance is the key to keeping it safe, efficient, and compliant. Even the best-designed systems can lose performance over time if filters clog, ducts accumulate residue, or airflow becomes restricted. Regular servicing ensures your equipment continues to protect both your employees and your production environment.
- Regular LEV Testing
Under COSHH regulations, every Local Exhaust Ventilation (LEV) system must be tested at least once every 14 months. These tests verify that your extraction system is effectively controlling airborne contaminants and remains compliant with HSE standards. Western Air Ducts provides comprehensive LEV testing and detailed performance reports to ensure your system passes every audit confidently. - Preventative Maintenance
Scheduled maintenance prevents costly downtime and unexpected breakdowns. Regular inspection of fans, filters, and ducting helps detect issues early — such as reduced airflow, motor wear, or filter damage — before they affect air quality or energy efficiency. - Filter Replacement & Cleaning
In food environments, hygiene is paramount. Filters should be cleaned or replaced according to manufacturer specifications to maintain performance and prevent the build-up of product residues that could contaminate the workspace. - System Upgrades & Retrofits
As production grows, your air quality needs may change. Western Air Ducts can upgrade existing systems with modern fans, controls, or filtration technology to improve efficiency, reduce energy use, and enhance compliance with the latest HSE and ATEX standards.
Our dedicated aftercare and maintenance packages are designed to keep your system operating at its best — extending its lifespan while ensuring a cleaner, safer working environment.
Conclusion: Clean Air for Safe, Efficient Production
Clean air is the foundation of a safe, compliant, and productive food and beverage facility. The right dust and fume extraction system not only protects your workforce and equipment but also safeguards product quality and ensures full regulatory compliance under COSHH, HSE, and ATEX standards.
Whether you’re managing a small bakery or a large-scale food manufacturing plant, investing in a well-designed extraction system pays off in reliability, hygiene, and long-term efficiency.
At Western Air Ducts, we specialise in delivering complete air quality solutions — from system design and installation to LEV testing, maintenance, and compliance support. Our tailored approach ensures your system meets your exact operational and safety requirements.
Ready to create a cleaner, safer working environment?
Contact Western Air Ducts today to book a free on-site consultation and discover how our bespoke air extraction systems can help your food or beverage facility stay safe, efficient, and fully compliant.
