Industrial extraction

Many industrial production processes release dust, vapors, gases, smoke, or moisture. When these substances spread through the production environment, they can affect employee safety, machine reliability, and the quality of the production process.

A well-designed extraction system captures these pollutants as close to the source as possible and removes them in a controlled manner or further processes them. The result is a safe, clean, and energy-efficient production environment where people, machines, and processes can perform at their best.

The Callens Group has been delivering custom industrial extraction systems for 60 years. From concept engineering and installation to service and maintenance, you can rely on a single partner throughout the full life cycle of your installation.

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When is industrial extraction important?

An industrial extraction installation is required in production environments where significant amounts of dust, vapors, gases, smoke, mist, or moisture are released. Think of sectors such as pharmaceuticals, waste & recycling, and paper & cardboard manufacturing.

Depending on the application, the released substances are extracted directly at source, transported, and, if needed, further treated or filtered. The techniques used depend on the nature of the pollution, its concentrations, the safety requirements, and the applicable environmental legislation.

A well-designed extraction system improves safety, protects product quality, reduces employee exposure, and contributes to a reliable, energy-efficient production environment.

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Typical challenges where industrial extraction adds value

  • Capturing dust at source to prevent it from spreading throughout the production environment.
  • Safely ventilating and extracting air from ATEX zones without compromising operational reliability or energy efficiency.
  • Protecting employees from harmful or disruptive emissions.
  • Keeping machines and installations free from dust build-up or contamination.
  • Meeting the safety, environmental, and permit requirements.

Extraction for industrial applications

An extraction system is only effective when dust, vapors, and other pollutants are captured before they can spread through the production environment.

That is why the Callens Group develops industrial extraction systems that are fully aligned with the nature of the emissions, the production environment, and the applicable safety and permit requirements.

From concept engineering and engineering through installation, service, and maintenance, we support the entire process as an EPCS integrator. This gives you an extraction solution that protects employees, machines, and production processes as effectively as possible.

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Solutions

Our solutions for industrial extraction

Industrial extraction includes different techniques for removing or further treating dust, vapors, gases, smoke, and moisture in a controlled way. Depending on the application, we combine multiple techniques into one integrated air technology solution.

Callens Lucht Extractie Mydibel Fresh Moeskroen PRJ240216 2

Industrial dust extraction

Dust released during production processes can negatively affect safety, product quality, and installation reliability. Our industrial dust extraction systems capture dust as close to the source as possible and prevent it from spreading through the production environment.

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Gas and vapor extraction

Many industrial processes release gases and vapors that can be harmful to employees, installations, or the environment. The Callens Group develops extraction systems that safely capture, remove, and, where necessary, further treat these emissions, fully aligned with the properties of the released substances and the applicable emission and permit requirements.

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Water vapor extraction

Production processes that release a lot of moisture can lead to condensation, corrosion, mold growth, and an unpleasant working climate. With a well-designed water vapor extraction system, excess moisture is removed in a controlled way, so that production conditions remain stable and machines and buildings remain reliable.

More about water vapor extraction

Time for a breath of fresh air? Our specialists are happy to think along with you.

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THE CALLENS GROUP IN NUMBERS

One partner. 60 years of expertise. Total peace of mind.

With the Callens Group, one partner takes responsibility for the entire process: from concept engineering to installation, including service and maintenance. This integrated approach combines technical expertise, project experience, and a strong service organization.

+500 projects per year

Service and support within 2 hours

+400 qualified team members

60 years of experience in EPCS projects

Always close to customers with 13 locations

Technology-independent advice

How does industrial extraction contribute to a more sustainable production environment?

A sustainable extraction system starts with an efficient design. By extracting dust, vapors, and gases as close to the source as possible, harmful emissions are captured as effectively as possible with the lowest possible air flow rate and energy consumption.

Based on that vision, the Callens Group develops industrial extraction systems that combine safety, energy efficiency, and sustainability. Wherever possible, we recover heat from the extracted air, optimize air flow rates, and assess whether the filtered air can be reused inside the building. In this way, we not only reduce energy consumption but also increase the efficiency of the entire installation.

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Extraction systems sometimes remove large volumes of heated air. When the air is suitable for reuse after filtration, it can be blown back into the building. If that is not possible, we examine how the available heat can be recovered as much as possible for other applications in your production environment. This reduces your primary energy consumption and increases the overall efficiency of your installation.

By positioning extraction hoods as close as possible to the emission source, the required air flow rates remain limited, the installation consumes less energy, and harmful substances do not spread throughout the production environment. Where standard components do not suffice, our engineers also design extraction hoods fully tailored to your production process.

A well-designed extraction system helps companies meet applicable emission, environmental, and permit requirements. Depending on the application, we combine source extraction with high-quality filtration techniques so that dust, vapors, and other pollutants are removed in a controlled way. This means you invest in a safe, future-proof, and sustainable production environment.

Ecosynth Deinze Afzuiging labokasten 3

A well-considered technical concept for industrial extraction starts on your site

Plans and technical data sheets only tell part of the story. That is why the Callens Group always looks beyond theoretical calculations or third-party studies.

Our engineers visit the site for every project to thoroughly analyze the production environment and emission sources. Among other things, we map the type and concentration of dust, vapors, gases, or water vapor, the air flow rates, airflows, heat load, and the interaction between the different production processes. We also study where the emissions arise and how they can be captured most efficiently at source.

Based on these measurements and practical insights, we develop a correctly dimensioned extraction concept that is fully aligned with your production process, the applicable safety and permit requirements, and the desired energy efficiency. This gives you an extraction system that delivers maximum safety, reliability, and performance in everyday operation.

Working with the Callens Group means peace of mind, reliability, and certainty

An industrial extraction system must continue to function safely, reliably, and energy-efficiently for many years. That is why it is best to choose a partner who not only designs the right extraction solution, but also ensures high-quality execution, service, and maintenance. You will find that combination at the Callens Group.

At the Callens Group, you have a single point of contact for your entire steam project: from the first analysis to installation, including service and maintenance. This keeps the process clear and reduces the need for separate coordination between different parties.

The Callens Group is not tied to a single brand, manufacturer or technology. This allows us to select the solution that is technically and economically the most attractive for each project. To do so, our engineers take account of energy prices, grid capacity, water quality, emission targets, available space and total cost of ownership to provide you with a solution that integrates perfectly into your production environment.

With more than 120 service and maintenance specialists, the Callens Group has one of the largest service teams. Preventive maintenance, interventions, remote monitoring and an extensive stock of spare parts ensure that your steam installation remains maximally available and that unplanned downtime is kept to a minimum.

The Department of Technology is the Callens Group’s innovation center. Here, new developments in heat technologies are assessed for their technical feasibility and their added value for industrial applications. Only proven technologies ultimately find their way to customers.

With 13 locations across Belgium, the Netherlands and France, we combine the benefits of an international group with the proximity of local teams. This allows us to act quickly.

Projects with industrial extraction installations

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Air technology Extraction Gas and vapor extraction

Extraction system takes on hazardous propellants

Capacity40,000 m3/h
Zone typeAtex
Callens afzuigsysteem 1
Air technology Extraction Industrial dust extraction

One extraction system, twice the benefit

Maximum flow rate9,000 m3/h
Maximum vacuum3,200 Pa
Callens ventilatie labo 1
Air technology Extraction Gas and vapor extraction

Laboratory puts ventilation to the test

Extraction ratemax. 18,000 m3/h
Injection ratemax. 18,000 m3/h

Questions? We have the answers.

For an animal-feed producer, the Callens Group developed an industrial dust extraction installation that extracts dust during the actual mixing process. The installation processes a maximum airflow rate of 9,000 m³/h and routes the extracted dust through a compressed-air cleaning filter. The cleaned air is then blown back into the production environment in line with the applicable requirements for maximum dust concentrations. The separated dust is also valorized. Instead of being discharged as waste, the dust is collected through a cleaning system and reused as a residual product. This allows the installation to combine a clean production environment with more efficient use of raw materials and a maximum vacuum of 3,200 Pa. 

Every project starts with a technical study day at your site. Our engineers analyze the emission sources, the properties of the dust, the airflows, the required capture velocities, and the applicable safety and permit requirements. Based on that analysis, we develop a dust extraction concept that is fully tailored to your production process. As an EPCS integrator, the Callens Group then takes care of the entire process: from concept engineering and detailed engineering to installation, commissioning, service, and preventive maintenance. Want to discuss your industrial dust extraction project?

Yes. Depending on the properties of the dust and the production process, the separated dust can be collected for reuse, recycling, or valorization. This reduces the amount of waste and can also create added economic value. During concept engineering, the Callens Group examines whether dust recovery is technically and economically feasible within your production process.

Want to know whether dust recovery is possible in your production environment? Our specialists will be happy to review the possibilities.

Filter service life depends on the amount of dust, operating hours, and the type of production process. Waiting until filters are fully saturated often leads to greater pressure drop, an increase in energy consumption, and reduced extraction capacity. During preventive maintenance, filter performance is closely monitored. This ensures that filters are replaced at the right time and that the installation remains reliable, energy efficient, and safe.

Combustible dust particles that are released during a production process create an explosive atmosphere. In these situations, the dust extraction installation must comply with the applicable ATEX directives. During the engineering phase, the Callens Group analyzes the dust properties, the process conditions, and the applicable safety regulations. Based on that analysis, we develop a dust extraction system that is fully aligned with the required safety standards.

The required extraction flow rate depends on the amount of dust released, the properties of the dust particles, the position of the emission source, and the desired capture velocity. Too low an airflow rate will not satisfactorily capture the dust, while too high an airflow rate consumes unnecessary energy. That is why the Callens Group starts every project with an on-site visit. Based on measurements and process analyses, our engineers determine the optimal extraction flow rate and dimension the installation so that safety, energy efficiency, and performance are perfectly balanced.

Want to know which extraction flow rate your production process needs? Our experts will be happy to advise you.

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