How smart LEV tech is transforming industrial energy savings
One of the most overlooked contributors to energy inefficiency in industrial settings is air handling, particularly in processes that require the removal of harmful fumes, dust or particulate matter from the work environment. Local Exhaust Ventilation (LEV) systems, long used to ensure workplace safety, are now being reengineered for another priority: reducing energy consumption.
A new generation of LEV technology is showing that enhanced air filtration doesn’t have to increase energy costs. Instead, it can lead to significant savings of up to 30 percent, according to recent industrial case studies.
The importance of energy efficiency in manufacturing
The cost of electricity in many industrial economies has increased sharply, driven by energy supply volatility, geopolitical factors and long-term shifts toward decarbonization. In the United Kingdom, electricity prices are projected to increase by over 13 percent annually for the next five years, putting financial strain on producers across sectors from food to fabrication.
For operations with extensive heating, cooling and extraction demands, these rising costs threaten profitability. Traditional LEV systems often run at constant fan speeds regardless of actual need, consuming more energy than necessary throughout the workday. Many older systems also lack feedback mechanisms that respond to changes in filter load or production intensity.
This inefficiency has two major consequences. First, it inflates energy bills, sometimes accounting for 20 percent or more of a facility’s electricity use. Second, it works against sustainability goals by increasing emissions associated with energy consumption, even when the air quality inside the plant meets safety standards.
Innovations in LEV systems: The Geovent MultiBox IV
The core of the transformation in air filtration lies in the evolution of the LEV system itself. Traditional setups relied on fans with fixed speeds, resulting in energy consumption that didn’t reflect actual usage patterns.
The Geovent MultiBox IV addresses that need. At its center is a sensor-based feedback loop that adjusts fan speed according to demand. This reduces waste while maintaining compliance with air quality standards.
One of its standout features is the ability to control multiple workstations and extraction arms from a single unit. In dynamic environments where stations are frequently activated or deactivated, the system directs airflow only where it is needed.
The design also resolves a common maintenance challenge. When filters become blocked, many systems fail to respond, leading to performance loss and increased energy use. The MultiBox IV includes pressure sensors that alert users to blockages, making routine checks more effective and avoiding unplanned downtime.
Case study: Moores Biscuits’ implementation of energy-efficient LEV
Moores Biscuits, a UK-based heritage biscuit manufacturer, faced a challenge familiar to food producers. Its facility required steady air extraction to manage flour dust and fine particulates, but its existing LEV system lacked responsive control features and was no longer cost effective.
Moores partnered with MCG Environmental Engineering to modernize its approach. The project involved installing a Geovent MultiBox IV system, customized to the site layout and workload patterns. The installation included multiple extraction arms, ATEX-certified filters and a centralized control unit with variable fan speed functionality.
Following the upgrade, Moores reported a 30 percent reduction in energy use related to air handling. Working conditions also improved, with lower dust levels and better overall air quality. Maintenance became more predictable due to automatic filter monitoring, and the company reduced its exposure to sudden breakdowns and costly downtime.
Future LEV systems will likely integrate with broader energy management platforms, enabling real-time adjustments across the facility based on production schedules and utility prices. They will also generate performance data that supports predictive maintenance and strategic decision-making.
Regulations are expected to become stricter, with higher air quality and emissions standards shaping how facilities approach ventilation. ATEX certification and ISO compliance will remain critical, particularly in food, chemical and heavy manufacturing. Finally, facilities that modernize their air handling infrastructure will be better positioned to meet ESG expectations while protecting their bottom line.
Sources:
Press Release