Industrial dust extraction

Numerous industrial processes, such as grinding, mixing, screening, conveying, sawing, or packaging generate fine dust. Without a well-designed extraction system, dust particles spread through the production environment, soiling machines, exposing employees, and putting product quality under pressure.

The Callens Group develops industrial dust extraction systems that capture dust at source and remove or filter it in a controlled manner. This creates a clean, safe, and energy-efficient production environment where people, machines, and processes can perform at their best.

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When is industrial dust extraction useful?

Not every dust particle presents the same risk. The size, concentration, and properties of the dust determine how quickly dust spreads through a production environment and how it affects employees, machines, and the production process. That is why every dust emission requires a well-considered extraction strategy.

Industrial dust extraction captures dust as closely as possible to the emission source and prevents dust particles from spreading further through the production environment. Depending on the application, the dust is then filtered, collected, or safely removed.

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For which applications?

  • Production processes that release dust during grinding, mixing, screening, or conveying.
  • Production environments where dust can affect product quality.
  • Installations where dust build-up causes failures or wear.
  • Production environments with potentially explosive dust particles (ATEX).
  • Production processes that must meet strict safety, hygiene, or permit requirements.
  • Workplaces where employees must be protected against dust exposure.

Technical specifications for industrial dust extraction

As soon as dust particles are released, they must be captured and removed in a controlled manner as quickly as possible. The positioning of the extraction points, the airflow rate, and the selected filtration technology all determine how efficiently dust is removed from the production environment.

The Callens Group develops industrial dust extraction systems that are fully aligned with the properties of the dust, the process conditions, and the desired air quality. Source extraction, dust transport, and filtration form one integrated whole. The result is an installation that combines maximum capture with minimal energy consumption.

Techniques

Source extraction.

Custom extraction hoods.

Centralized and decentralized dust extraction.

Cartridge filters and bag filters.

Cyclone separators.

ATEX-compliant dust extraction.

Benefits

Benefits of industrial dust extraction

When dust spreads through a production environment, it affects safety, machine reliability, and the quality of your end product. A well-designed dust extraction system prevents dust from building up or spreading and supports a safe and efficient production environment.

Less dust dispersion

By extracting dust at source, dust particles cannot spread through the production hall. This results in a cleaner production environment and limits contamination of products, installations, and buildings.

Better employee protection

Dust exposure can affect employee health and working comfort. Efficient dust extraction reduces the concentration of dust particles in the working environment and contributes to a safer workplace.

Longer service life for machines and installations

Dust can accumulate in machines, electrical components, and production lines, causing more wear and failures. By continuously removing dust, installations continue to operate reliably for longer and maintenance costs decrease.

Less cleaning and maintenance work

When less dust spreads through the production environment, machines, air ducts, and buildings stay cleaner for longer. This reduces cleaning interventions and increases the availability of your production installations.

Higher operational continuity

A well-designed dust extraction system prevents dust from accumulating in production installations or critical process zones. This lowers the risk of failures and unplanned downtime, so that your production process keeps running reliably.

Compliance with safety and permit requirements

A well-considered dust extraction system helps you meet the applicable occupational safety, emission, and environmental permit requirements and ensures that you invest in a future-proof production environment that is ready for the increasingly stringent regulations.

Industrial dust extraction is custom work

There are many factors to consider when installing an industrial dust extraction system such as dust-particle size, concentration, density, and explosiveness. These properties, along with environmental factors such as temperature and airflows, determine how dust spreads through a production environment. That is why industrial dust extraction always requires a custom solution.

During an on-site visit, the Callens Group engineers analyze the entire production process. We map the emission sources, the dust properties, the airflows, the required capture velocities, and the applicable safety and permit requirements. Where needed, we also assess ATEX risks and the possibilities for heat recovery or energy optimization.

Based on this analysis, we develop a dust extraction system that is fully tailored to your production environment. We determine the optimal position of the extraction points, select the most suitable extraction and filtration technologies, and dimension the complete installation for maximum dust capture with minimal energy consumption. This gives you a safe, reliable, and energy-efficient solution that continues to perform optimally for years.

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Maintenance after installation

Even after installation, you can continue to rely on the Callens Group for maintenance and service, in cooperation with specialist partners.

During maintenance, we check the filters, extraction hoods, fans, air ducts, mechanical and electrical components, and control technology, among other things. We also closely monitor filter performance and pressure drop and remove dust accumulations where needed. This maintains extraction capacity, prevents unnecessary energy consumption, and lowers the risk of failures or unplanned downtime.

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Partnership

Why work with the Callens Group?

60 years of experience in EPCS projects

An independent integrator focused on your specific needs

Flexible project execution

Short decision-making lines and a personal approach

Unique service & maintenance support

Always close to customers with 13 locations

“A reliable indoor climate starts with a well-considered air technology design that is fully tailored to your production process.”

Projects with industrial dust extraction

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

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.