Fibreglass, also known as Fibre Reinforced Plastic (FRP) or Glass Reinforced Plastic (GRP), is a cornerstone of modern manufacturing in New Zealand. Its versatility and benefits make it an ideal material for an array of products such as boats, vehicle body parts, swimming pools, shower trays, and industrial storage tanks. However, while fibreglass products boast advantages such as corrosion resistance, lightweight construction, and thermal insulation, the manufacturing process poses significant challenges due to its inherent emissions of pollutants like overspray, hazardous fumes, and dust.

At Egmont Air, we’ve spent years working in industrial environments, alongside New Zealand’s fibreglass manufacturers, providing tailored air quality solutions that ensure worker safety, compliance with environmental standards, and streamlined production processes. Below, we’ll explore the challenges of fibreglass manufacturing, including hazardous fume extraction and how our range of  spray booths, extraction systems, and dust collectors offers the ultimate solution.

Fibreglass Production Process: A Versatile but Complex Process

Fibreglass manufacturing typically involves three key steps:

1. Gelcoat Application: The process begins with applying a gelcoat to a mould. This layer, often sprayed or brushed, forms the outer surface of the finished product, giving it the gloss and durability seen in boats, vehicle panels, or bathroom fixtures. However, this step generates overspray and a high concentration of hazardous fumes due to the polyester resin and associated chemicals.
2. Laying-up or Laminating: Fibreglass strands, combined with a resin mixture, are usually sprayed or wound onto the mould in layers to create the structural form. The chemical reaction during this stage releases extreme levels of hazardous fumes, requiring robust ventilation systems.
3. Finishing: Once the fibreglass hardens, the product undergoes trimming, drilling, or grinding to refine its shape and surface. This final step generates fine dust particles, which, if not properly managed, can pose serious health risks to workers and compromise air quality.

Navigating the Challenges of Fibreglass Production

Fibreglass manufacturers face a triad of air quality challenges, including overcoming contaminated air to ensure workplace safety. Overspray control is a significant issue, as excess gelcoat and resin spray, if not effectively managed, can result in material wastage, workplace contamination, and serious respiratory hazards for operators. Hazardous fume mitigation is another critical concern, with the resin and hardening agents used in the process emitting fumes containing styrene monomer and other volatile organic compounds (VOCs). These emissions can irritate respiratory systems and accumulate to dangerous levels without proper fume mitigation systems in place. Additionally, dust management is essential, as the trimming and grinding of fibreglass produce ultrafine dust particles that, when inhaled, can cause chronic respiratory issues. These challenges are critical concerns for those manufacturing companies who rely on fibreglass and who place a high value on worker safety and demonstrate their commitment by investing in advanced extraction solutions with Egmont Air  to maintain compliance with health regulations and protect their teams.

Egmont Air’s Comprehensive Air Quality Solutions

At Egmont Air, we understand the unique demands of fibreglass manufacturing and have developed air quality systems specifically designed to address each stage of the process. Here’s how we can help:

1. Spray Booths: Precision Overspray Control

Our solutions for designated spray areas are engineered to capture overspray effectively while providing a controlled environment for gelcoat application.

• Advanced Extractors: Egmont Air’s overspray solutions feature multi-stage fume extractors that trap airborne particles, ensuring clean air is recirculated into the workspace.
• Custom Sizing: Whether you’re producing large-scale products like boats or smaller items like bathroom fittings, our spray booths can be tailored to fit your requirements. 
• Improved Efficiency: By reducing overspray, many of our customers have reported reduced material wastage and more consistent finishes on their products.

2. Designated Spray-Paint Area Extraction: Fume Control Made Easy

The laminating process produces hazardous fumes that demand specialised extraction systems to protect workers and maintain compliance.

• High-Performance Ventilation: Our extractors for open spray areas are designed to remove fumes at the source, preventing the build-up of styrene monomer and other VOCs in the workspace.
• Quiet, Energy-Efficient Operation: Unlike conventional systems, Egmont Air’s extraction units operate quietly and efficiently, making them a seamless addition to your production line.
• Real-World Success: For many companies we work with, our fume extraction systems have dramatically improved air quality, reducing exposure risks and enhancing worker well-being.

3. Dust Collectors: Keeping Your Workspace Clean

Trimming, grinding, and drilling fibreglass creates a significant amount of fine dust that can settle on surfaces, enter machinery, and pose health risks – extraction is essential.

• Powerful Dust Extraction: Egmont Air’s cartridge dust collectors are built to handle high volumes of fine particles, ensuring a clean and safe working environment.
• Customisable Configurations: From small-scale operations to industrial facilities, our systems can be scaled to meet your specific needs.
• Enhanced Safety and Productivity: By maintaining a dust-free workspace, many manufacturers we work with have seen improved worker productivity and reduced downtime caused by equipment contamination.

Why Choose Egmont Air?

As a family-run business with deep roots in New Zealand’s manufacturing community, Egmont Air combines technical expertise with a personal touch. Here’s why leading fibreglass manufacturers trust us:

• Proven Experience: With decades of experience working with industries like fibreglass, we understand the challenges and nuances of your operations.
• Tailored Solutions: Every workspace is unique. That’s why we take the time to design air quality systems that align perfectly with your production needs.
• Commitment to Excellence: From consultation to installation and beyond, our team is dedicated to delivering reliable solutions that stand the test of time.
• Local Support: As a locally owned and operated business, we pride ourselves on building long-term relationships with our customers, offering ongoing support whenever it’s needed.

Transforming Fibreglass Manufacturing with Egmont Air

Fibreglass may be an essential material in modern manufacturing, but its production challenges can’t be ignored. Overspray, hazardous fumes, and dust not only jeopardise worker safety but also threaten operational efficiency.

At Egmont Air, we specialise in turning these challenges into opportunities for improvement. Whether it’s a state-of-the-art open spray area solution to enhance product quality, an fibreglass fume extraction system to safeguard air quality, or a fibreglass dust collector to maintain a clean workspace, our solutions are designed to keep your fibreglass operations running smoothly.

For manufacturers who rely on fibreglass to manufacture their products, partnering with Egmont Air has meant safer workplaces, streamlined production, and long-term compliance with health and safety standards.

Contact Us Today

Ready to transform your fibreglass manufacturing process? Contact Cameron, Todd or Richard at Egmont Air to discuss your air quality needs. Our team of experts is here to help you create a safer, more efficient, and environmentally friendly workspace tailored to your unique requirements.

Let Egmont Air take the pressure off your fibreglass operations—so you can focus on building the products that keep New Zealand moving forward.