Streamlined dust extraction to boost efficiency

One Smart System: How Nederman Helped Tiflex Streamline Dust Extraction and Boost Efficiency

When production efficiency, compliance, and energy management all come under pressure, it takes a smart solution to bring everything together.

Tiflex Ltd. is a long-established manufacturer specialising in rubber and cork-based products. With multiple production lines and varied material processes, maintaining a safe, compliant, and efficient working environment is a constant priority.

Over time, the company’s legacy dust extraction setup had become inefficient and difficult to manage. Four separate systems occupied valuable floor space, complicated maintenance, and failed to meet ATEX compliance standards. A particular concern given the combustible nature of cork, rubber, and plastic dust.

Challenges due to using four separate dust extraction systems

When Tiflex approached Nederman, they were operating four independent dust extraction systems in one section of their factory. These systems created several challenges:

• Excessive floor space use
• Limited access for maintenance
• Inconsistent extraction performance
• No ATEX-rated components, increasing explosion risk

Although formal ATEX testing had not been carried out, Nederman’s experience with similar materials guided the design approach from the start. Safety, compliance, and long-term efficiency were placed at the core of the project.

Turnkey dust extraction solution from Nederman

Nederman provided a complete, turnkey solution, from system design through to installation and commissioning. At the heart of the new system is the Nederman LBR-S filter unit, managing dust from 13 extraction points, with at least nine running continuously.

ATEX Compliance and worker safety

Handling combustible dust such as cork, rubber, and plastic carries inherent risks, including potential explosions. To address this, Nederman designed the system to be fully ATEX-compliant, ensuring that every component meets stringent regulatory requirements.

Key safety measures include:

• CAR-Z isolation valve, installed at a single designated point in the ducting. In the unlikely event of an explosion, the valve isolates the affected section, preventing propagation and protecting both personnel and equipment.
• Strategic placement of extraction points and filters, optimised to minimise dust accumulation and reduce ignition risks.
• Complete automation solution based on Insight Control and Nederman SAVE, enabling intelligent airflow control and ensuring ATEX-compliant, fail-safe system operation that prevents potential hazards.
• Digital Monitoring with the cloud-based Nederman Insight platform for performance tracking, real-time alarm notifications, and predictive maintenance using live and historical data.

This proactive approach ensures not only regulatory compliance but also the highest level of protection for workers, giving Tiflex confidence that their production environment is safe, controlled, and sustainable.

Optimising performance with Nederman SAVE

To further enhance performance, the installation includes Nederman SAVE for intelligent airflow control that automatically adjusts airflow on demand based on real-time process signals and damper positions, ensuring extraction only when needed, resulting in:

• Lower energy consumption
• Reduced noise and equipment wear
• Less maintenance downtime
• Maintaining transport velocities in the ductwork

As the system is also supported by Nederman Insight, the customer benefits on top of better operational efficiency also on improved production planning capability by having a detailed overview on the utilisation of his machines.

System advantages

The integrated system delivered multiple operational benefits, including:

• ATEX compliance for combustible dust handling protects workers and production
• CAR-Z explosion isolation valve, to contain explosions at a single point
• Nederman SAVE maintaining minimum transport velocities and preventing dust buildup in the ductwork
• Reduced floor space by consolidating four systems into one
• Improved accessibility for maintenance and inspections
• Enhanced energy efficiency through intelligent airflow control
• Real-time data and monitoring for proactive system management

Why Tiflex chose Nederman for their dust extraction solution

Tiflex invited several suppliers to tender for the project. Nederman was the only provider capable of delivering a complete, single-system solution, simplifying project coordination and ensuring consistent quality throughout.

Our ability to combine ATEX safety, intelligent energy control, and real-time monitoring in one system made Nederman the clear choice. Tiflex valued our end-to-end expertise and commitment to both operational excellence and safety.

The results: long-term sustainability and cost savings

From commissioning in April through to July, the new system achieved measurable performance improvements:

• 67,000 kWh energy saved
• £9,400 reduction in operating costs
• Up to 70% lower energy usage during peak times

These results demonstrate the combined impact of centralised extraction and intelligent control technology in delivering long-term sustainability and cost savings.

Through close collaboration and technical innovation, Nederman helped Tiflex transform a fragmented extraction system into a single, intelligent, and compliant dust control solution.

By integrating smart airflow management, real-time monitoring, and ATEX-certified components, Tiflex achieved greater safety, operational efficiency, and energy performance.

Nederman’s integrated approach to clean air solutions gives manufacturers the confidence to operate safely, efficiently, and sustainably.

If you’re seeking a complete dust extraction solution that improves performance, ensures compliance, and delivers measurable savings, contact our clean air experts today to discuss how Nederman can support your operation.