In many industrial workshops, dust and fume extraction systems often go unnoticed—working quietly in the background, presumed effective until something goes wrong. At Egmont Air, we’ve helped countless businesses realise the true cost of relying on outdated technology. The reality? Old and inefficient industrial dust extraction systems could be draining your bottom line, hindering productivity, and jeopardising your team’s health.
The Hidden Costs of Outdated Systems
If your system is still running on outdated belt-drive fans or patched-together ducting, you’re likely paying far more than necessary in operational costs. Traditional paddle-blade, belt-drive fans are energy guzzlers. In contrast, high-efficiency direct-drive fans with reverse vane impellers deliver significant savings. The efficiency difference can be substantial—reverse vane impellers offer up to 25% energy savings over traditional paddle-blade designs, and direct-drive systems contribute an additional 10% by eliminating energy losses inherent in belt-drive transmissions. Given that most dust extraction systems operate continuously throughout the day, the savings add up fast. For example, a 22kW (30Hp) high-efficiency fan running over 2,000 hours annually can cut energy costs by up to 30%, equating to savings of around NZ$4,000 per year based on an energy rate of 30c/kWh.
Modern technology has transformed how industrial dust extraction can work for you. Egmont Air’s Eco-power range, fitted with a Variable Speed Drive (VSD) and pressure transducers, dynamically adjusts airflow based on machine usage. A 20% reduction in airflow can lead to a 50% drop in power use—translating to over $6,600 in annual savings based on total usage of over 2000hr/yr at 30c/kwHr. Best of all, these systems can be retrofitted, revitalising your current setup without a complete overhaul.
Beyond power inefficiency, there’s the issue of reliability. We’ve seen entire operations grind to a halt due to failures in aged fume extraction systems. For one client, a clogged and neglected filter caused a cascading system failure, stopping production for nearly 24 hours. It’s a stark reminder that ignoring system health can lead to significant and sudden losses.
Poor Suction, Poor Results
One of the more deceptive issues with ageing systems is reduced suction performance. It often goes unnoticed until you realise your workshop dust extractor isn’t keeping pace with your machinery. Poor suction means sawdust, weld fumes, or sanding residue aren’t being efficiently removed—leading to faster wear on consumables like blades and sanding belts, as well as reduced machine performance.
Mismatched ductwork, added over time to accommodate new tools, creates a chaotic airflow environment. Inconsistent airflow is a common issue in workshops expanding without a strategic layout. That’s why we offer a full on-site consultancy: to assess, rebalance, and optimise your system. Even small tweaks—like replacing with correct ducting, recalibrating a fan or upgrading a dust extraction hood—can yield immediate performance improvements.
Breathing Easy: Complying with Health Regulations
Effective extraction isn’t just about machine performance—it’s about people. Exposure to airborne particulates and welding fumes is a serious health hazard. Clean air enhances concentration, reduces sick leave, and builds a reputation for care and professionalism—crucial in industries facing skill shortages. Complying with welding fume regulations in NZ isn’t optional; it’s a legal and ethical obligation. Whether you’re looking to comply with welding fume regulations for the first time or reassess an old setup, our team can ensure your system meets all standards. From high-efficiency fume extraction systems to localised extraction arms and fume hoods, we tailor solutions that protect your team’s health.
Maintenance Matters
Filters may be out of sight, but they shouldn’t be out of mind. Whether you have an automated self-cleaning mechanism or not, filters require attention. Blocked filters choke airflow, lower efficiency, and eventually cause system failures. Our scheduled maintenance services, including pressure monitoring and alert systems, keep your dust extractor systems operating at their best.
Ready to Upgrade?
At Egmont Air, we understand that a fume extraction system isn’t just a box to tick—it’s a critical component of your operational success. With decades of experience designing, installing, and maintaining advanced industrial dust extraction systems, we deliver solutions that save money, improve productivity, and support worker health.
Don’t wait for a breakdown to realise your system is holding you back. Talk to Cameron, Todd, or Richard today and find out how we can help future-proof your workshop.