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In industrial environments, a reliable extraction system is not just a convenience — it is a fundamental requirement for safety, efficiency and regulatory compliance. Yet, many workplaces continue to struggle with recurring air-quality problems, system failures or unnecessary expenses due to preventable mistakes in their dust or fume extraction setup.
At MAE Air Systems, we’ve spent decades designing, installing and servicing industrial extraction systems across Ireland. Over the years, we’ve seen the same issues occur again and again — often costing businesses time, money and productivity.
This blog explores the most common mistakes organisations make with their extraction systems, and how MAE helps prevent them through expert design, equipment selection and ongoing maintenance.
1. Choosing the Wrong Type of Extraction System
One of the biggest mistakes businesses make is choosing a system based on cost or convenience rather than suitability. A workshop, welding bay, laboratory and production line all generate different types and volumes of airborne particles. Using the wrong system typically results in:
- Poor dust and fume capture
- Increased energy consumption
- Frequent filter blockages
- Reduced extraction efficiency
- Higher long-term costs
MAE’s engineers take time to understand each workspace and recommend equipment tailored to your operations — ensuring effective air control from day one.
2. Underestimating Airflow Requirements
Incorrect airflow is a leading cause of system underperformance. Too little airflow, and dust remains in the working environment. Too much, and you burn unnecessary energy while wearing out filters prematurely.
We often encounter systems installed without proper airflow calculations or velocity tests. At MAE, we conduct detailed on-site assessments to determine:
- Air volume requirements
- Ducting size and layout
- Capture velocity
- Filter capacity
- Pressure drop
This ensures the system is neither underpowered nor overpowered — just right for your space.
3. Poorly Designed or Installed Ducting
Even the best extraction unit cannot perform well if the ducting is poorly designed. Incorrect bends, long horizontal runs, undersized pipes or air leaks can drastically reduce efficiency.
Common ducting mistakes include:
- Sharp 90-degree bends
- Incorrect pipe diameters
- Unsupported ductwork
- Leaking joints
- Excessive vibration
MAE designs ducting layouts that maximise airflow and reduce resistance, ensuring the entire system performs as intended.
4. Not Replacing Filters on Time
Filters are the heart of any extraction system. Over time, they become clogged with dust or debris, reducing airflow and putting pressure on the motor and fan.
Signs of overdue filter replacement include:
- Reduced suction power
- Higher energy bills
- Frequent blockages
- Increased noise
- Dust build-up around extraction points
With MAE’s range of filter bags, cartridges and specialist media, businesses can maintain peak performance while reducing wear on the system.
5. Ignoring Regular Maintenance
Many system failures are not due to poor design — they’re due to lack of maintenance. Just like machinery or vehicles, extraction systems need regular checks to ensure safety and compliance.
Neglect often results in:
- Unexpected breakdowns
- Poor indoor air quality
- Untreated leaks
- Fan or motor damage
- Costly repairs
MAE offers planned maintenance services, ensuring your system operates reliably and efficiently all year round.
6. Delaying Modernisation
Technology has evolved significantly over the past decade. Older systems use more energy, are harder to service and often rely on outdated components. Businesses that delay upgrades miss out on:
- Lower energy consumption
- Improved filtration
- Quieter operation
- Better system control
- Increased productivity
MAE helps clients transition to modern, efficient systems that deliver long-term savings and enhanced safety.
How MAE Air Systems Prevents These Mistakes
Detailed Site Assessments
We analyse your operations, workspace layout and specific risks before recommending a solution.
Bespoke System Design
Every system is engineered for optimal airflow, safety and efficiency.
Professional Installation
Our team ensures correct ducting, airflow balance and equipment setup.
High-Quality Spare Parts
From fans and blowers to flexible connectors and filters, we supply durable components for all system types.
Ongoing Servicing
Scheduled maintenance keeps your system compliant, efficient and problem-free.
MAE’s expertise ensures you get a system that performs reliably — without the costly mistakes that many businesses encounter.
Build a Safer, More Efficient Workspace with MAE
Avoiding the common pitfalls in extraction system design and maintenance starts with choosing the right partner. MAE Air Systems delivers tailored, efficient and reliable solutions that support safe, compliant and productive work environments.
If you’re planning a new installation, considering an upgrade or need support with an existing system, visit mae.ie or contact our team for expert guidance.