Case Study
Turnkey Dust Extraction System for a Leading Confectionery Manufacturer
Overview
Client: International Confectionery Manufacturer
Industry: Food Production / Confectionery
Project Overview: Design, fabrication, installation, and commissioning of a starch dust extraction and filtration system
Newsome was appointed to deliver a complete dust extraction and filtration solution for a leading international confectionery manufacturer. The project focused on the safe and efficient capture of starch dust generated within the TES production process. The new system was designed to centralise starch collection while ensuring strict compliance with ATEX Zone 22 regulations relating to combustible dust. Alongside safety and compliance, the installation had to deliver improved air quality, reduced operational noise, and minimal disruption to ongoing production activities.
Project Background and Objectives
Airborne starch particles present significant challenges in food production environments, not only as a hygiene and air quality issue but also due to their combustible nature. The client required an upgraded system to replace existing dust handling arrangements, with objectives to:
- Capture starch effectively at multiple points along the production line.
- Ensure safe containment and transfer of collected material.
- Achieve compliance with ATEX directives, including certified explosion protection.
- Minimise downtime and integrate smoothly with existing plant.
- Provide a low-maintenance solution with long-term energy efficiency.
This project formed part of the client’s wider commitment to workplace safety, regulatory compliance, and sustainable production.
System Design and Integration
Centralised Filtration Unit
The foundation of the installation was a bespoke Econojet filtration unit, designed specifically to handle the starch dust generated during production. This unit was positioned within a dedicated room on site, ensuring accessibility for operators and maintenance staff while isolating the filtration process from the wider production environment. The unit incorporated 60m² of antistatic PNF filter media across 36 flat pad elements, each measuring 1250mm in length. This extensive filter surface provided a large capture area, enabling high volumes of dust-laden air to be processed effectively while maintaining low pressure drop and long filter life.
Explosion Protection Measures
As the process involved combustible starch dust, compliance with ATEX Zone 22 regulations was a critical aspect of the system design. The Econojet unit was fitted with explosion relief panels, each certified to release pressure safely in the event of a deflagration. These panels were equipped with rupture indicators for ongoing monitoring, giving operators immediate feedback should a panel be activated. In addition, stainless steel hopper sections tapered to controlled discharges ensured that collected dust was safely transferred into downstream handling equipment, minimising the risk of secondary ignition sources.
Stainless Steel Ductwork
The system relied on a network of stainless steel ducting to transport dust-laden air from multiple collection points along the production line back to the central filtration unit. The ductwork was fabricated in 304-grade stainless steel with smooth bore construction, reducing internal resistance and minimising the risk of dust accumulation on internal surfaces. Careful design of duct diameters and gradients ensured that consistent capture velocities were achieved throughout the system, maintaining effective transport of particles to the filter unit. Clipped joints and stainless steel rod supports were used throughout, aligning with the client’s existing on-site standards for reliability and hygiene.
Explosion Relief Ducting
To complement the explosion relief panels on the filtration unit, ducting for pressure relief was fabricated from 2mm thick mild steel, painted for corrosion protection. These ducts were fitted with removable access panels, allowing operators to inspect the system following any release event and carry out essential maintenance without the need for full dismantling. This approach not only improved safety but also ensured system downtime was minimised in the event of an incident.
Reverse Jet Cleaning System
To keep the filter media operating at peak efficiency, a reverse jet cleaning system was integrated into the design. This system, powered by a certified compressed air header tank and ATEX-rated controller, automatically pulsed jets of compressed air through the filter pads whenever the differential pressure across the media indicated the need. This cleaning-on-demand approach ensured that the system maintained optimal airflow with minimal manual intervention, reducing maintenance requirements and extending filter life.
High-Capacity Extraction Fan
Air movement across the system was provided by a purpose-built 11kW extraction fan set. Designed to deliver an airflow of 6,375 m³/h at 3,500 Pa, the fan was equipped with a direct-driven backward curved impeller for efficient performance under high load. An IE3-rated motor ensured compliance with current energy standards while maintaining reliable operation at 3,000 RPM. The internal components of the fan were classified as Zone 22 compliant to safely handle dust-laden air, while the external housing was built to safe-area standards, offering a balance of safety and cost-effectiveness.
Noise Control and Airflow Management
Noise reduction was another important aspect of the system integration. A silencer was installed on the fan outlet to reduce operational noise levels, ensuring the system complied with workplace environmental standards. Airflow management was also enhanced through the installation of non-return dampers, which protected the system from backflow and maintained consistent directional airflow across all duct branches.
Logistics and Installation
New stainless steel ducting was routed from the extraction fan, passing through an internal wall and running parallel to the production line. The ductwork was designed with smooth bore stainless steel and carefully graduated diameters to maintain consistent capture velocities of 2 m/s. All joints were clipped, and stainless steel sheathed rod supports were used to align with existing site standards. A non-return damper was installed within the ductwork for backflow protection, while a silencer on the fan outlet minimised operational noise. Explosion relief ducting was fabricated from mild steel with removable access panels, allowing straightforward inspection and maintenance following any release event.
Installation was carried out with close coordination to avoid disruption to production. Penetrations through walls were sealed with weatherproof flashing plates, maintaining the integrity of the building envelope.
Commissioning and Perormance
Commissioning focused on airflow balance, capture velocity validation, and correct operation of the cleaning system. The reverse jet cycle was tested under full load conditions, confirming reliable filter performance. Visual inspection and pressure differential monitoring demonstrated efficient operation of all filter elements, while the hoppers collected starch dust effectively. Rotary valves (supplied by others) provided controlled discharge into designated receptacles.
The system delivered consistent capture across all collection points, maintaining air quality standards and improving environmental conditions for staff working in the TES production area.
Client Training and Support
Comprehensive documentation was provided, covering system layout, filtration operation, cleaning cycles, and maintenance requirements. Newsome engineers delivered on-site training to ensure client staff could monitor and operate the system effectively, including basic troubleshooting and fault diagnosis.
Key Outcomes and Benefits
Improved Dust Control
The new system delivers effective starch capture across the production line, ensuring airborne particles are contained and safely transferred to the collection unit. This has significantly reduced dust build-up within the production environment.
Enhanced Safety
ATEX compliance was achieved through the use of explosion relief panels, rupture detection systems, and antistatic filter media. The installation reduces the risk of combustible dust hazards and supports the client’s safety management strategy.
Operational Efficiency
Automatic cleaning via the reverse jet system reduces the need for manual intervention, keeping filters at peak performance and lowering maintenance costs. Energy-efficient fan design and optimised ductwork routing contribute to reduced running costs.
Improved Working Environment
Noise reduction measures and improved air quality have created a safer and more comfortable working environment, supporting both staff health and overall product integrity.
Long-Term Reliability
Stainless steel ducting and hopper construction ensure durability and hygiene compliance, while modular design features allow for straightforward future upgrades and maintenance access.
Client Testimonial
“Since my first project with Newsome, which was a full new dust extraction system in our packing hall back in 2016, there have been many further pieces of work carried out over a range of scales and complexities. My personal experience is that Newsome are competitive with costings, have a keen eye for suitable and performance-related design to meet (or exceed) customer requirements, communicate well through the project at the relevant key stages and then execute the installation professionally to a high standard. The teams of contractors that Newsome use are well received on our site – they work hard, are courteous and communicative and most importantly follow our site rules and work safely. It’s fair to say that if I’m in the market for something extract, duct, or dust handling related, Newsome are on my list of companies, and most likely the first that I will approach.”
Conclusion
This turnkey dust extraction installation demonstrates Newsome’s ability to deliver complex, ATEX-compliant systems for the food manufacturing sector. From initial design to final commissioning, the project met stringent technical, regulatory, and operational requirements, while supporting the client’s long-term goals for efficiency, safety, and product quality. The new system represents a significant step forward in air quality management, offering the client reliable dust control with lower maintenance needs and greater operational assurance.