Fume Extraction for Electronics Manufacturing:

Essential Guide with LEV Testing

Introduction to Fume Extraction in Electronics Manufacturing

In the world of electronics manufacturing, where precision and safety go hand in hand, ensuring clean air is not just a preference—it’s a necessity. Fume extraction for electronics manufacturing is a vital practice that protects both workers and delicate equipment from hazardous airborne contaminants. From soldering stations to coating lines, each process has the potential to release harmful fumes, which must be controlled through advanced ventilation systems and rigorous testing.

This guide aims to demystify fume extraction, highlight the importance of LEV (Local Exhaust Ventilation) testing, and provide a step-by-step understanding of how to implement safe air control systems in UK electronics manufacturing environments.
Why Fume Extraction is Critical in Electronics Facilities

Soldering, fluxing, and cleaning processes generate fumes containing substances like lead, rosin-based flux, and volatile organic compounds (VOCs). These pollutants can irritate the respiratory system, trigger asthma, and cause long-term health complications if not properly managed.

Aside from human health, airborne particles can also compromise the performance and reliability of sensitive electronic components, leading to increased product failure rates and costly recalls. Hence, an effective fume extraction system is indispensable for maintaining high-quality standards and occupational safety.

Overview of Harmful Fumes in Electronics Production

The fumes encountered in electronics manufacturing typically include:

• Rosin-based flux fumes: Can cause respiratory issues, skin sensitisation, and asthma.
• Lead particles: Especially concerning in wave soldering processes using lead-based solder.
• Isopropyl alcohol and other solvents: Common in cleaning, these can cause dizziness, nausea, and chronic health effects.

Each type of fume requires targeted extraction and filtration techniques to ensure air purity and worker protection.
Key Fume Sources in Electronics Manufacturing

Soldering Fumes

Soldering operations are among the most common in electronics production and generate significant levels of smoke containing particulate matter and harmful chemicals. These include tin and lead particles, flux residue, and rosin compounds.
Conformal Coating and Solvents

Used to protect circuit boards from moisture and contaminants, conformal coatings often emit toxic vapours. Solvents like xylene or toluene are also widely used in cleaning stages and can pose serious inhalation risks without proper ventilation.
Laser Cutting and Engraving

Laser-based processes can vaporise substrate materials, releasing ultrafine particles and chemical fumes. These require high-efficiency particulate filters and source capture arms to minimise exposure.

Health and Safety Regulations in the UK

COSHH Regulations and Workplace Exposure Limits
In the UK, the Control of Substances Hazardous to Health (COSHH) regulations mandate that employers take necessary measures to prevent or adequately control exposure to substances hazardous to health, including fumes. This involves conducting risk assessments, implementing engineering controls like LEV systems, and maintaining exposure levels below the Workplace Exposure Limits (WELs) defined by the Health and Safety Executive (HSE).

The Role of the HSE in Monitoring Air Quality

The HSE plays a crucial oversight role by setting compliance standards and offering guidance on LEV systems and testing. Employers are obligated to keep their fume extraction systems in optimal condition, and non-compliance can lead to fines, operational halts, or prosecution.
What is Local Exhaust Ventilation (LEV)?

Definition and Functionality of LEV Systems

Local Exhaust Ventilation (LEV) is a mechanical system designed to capture and remove airborne contaminants at their source before they can disperse into the workplace air. These systems typically include a hood or capture point, ducting, an air cleaning device (such as filters), and a fan or air mover.

Types of LEV Systems for Electronics Workspaces

• Benchtop Extraction Arms: Ideal for soldering stations, offering flexibility and precise fume capture.
• Enclosed Hoods: Used for processes with high fume concentrations.
• Downdraught Benches: Pull fumes down and away from the breathing zone.
• Portable Extraction Units: Useful for mobile operations and small production lines.

LEV Testing: Legal Requirements and Best Practices

Frequency and Methods of LEV Testing

UK law mandates that LEV systems be thoroughly examined and tested at least every 14 months. The testing includes checking airflow, pressure levels, filter integrity, and system containment. Tools such as anemometers and smoke generators are commonly used during assessments.

Who Can Perform LEV Testing?

Testing must be performed by a competent person, usually a trained professional with specific expertise in LEV systems. Many companies opt for certified LEV consultants or occupational hygienists who can issue valid test reports and certification.
Documentation and Reporting Standards

After each LEV test, a written report must be produced and retained for a minimum of five years. This report should detail:

• The condition and performance of the LEV system
• Any repairs or adjustments made
• Recommendations for improvement
• Test results and date of testing

Selecting the Right Fume Extraction System

Factors to Consider: Volume, Chemicals, Layout
Choosing a suitable fume extraction setup depends on:

• Volume of production: High-throughput environments may require centralised systems.
• Chemical properties: Different fume types need specific filters (e.g., HEPA, carbon).
• Workspace layout: Fixed arms may be ideal for static stations; mobile units suit flexible spaces.

Installation and Maintenance of Fume Extraction Equipment

Professional Installation Guidelines
For best performance, installation should be done by experienced technicians. Placement of capture hoods, duct routing, and power supply must align with the manufacturer’s specifications and workplace layout.
Routine Maintenance and Filter Replacement

Maintenance schedules must include:

• Filter inspection and replacement (HEPA, carbon filters)
• Fan and motor checks
• System airflow testing

Failure to maintain equipment can lead to system inefficiency and health risks.

Energy Efficiency and Environmental Impact

Energy Saving Tips for Fume Extraction

• Use automatic sensors to switch on systems only when in use.
• Maintain optimal ducting design to reduce air resistance.
• Opt for low-energy motors and fans with variable speed control.

Reducing Environmental Footprint with Proper Ventilation

Proper extraction not only protects health but also minimises the release of untreated fumes into the environment. Recyclable filter cartridges and eco-friendly systems contribute to sustainable manufacturing.

Training Employees on Fume Safety and LEV Usage

Conducting Safety Briefings and SOPs

Employees should undergo initial and periodic training on:

• The importance of fume extraction
• Safe operation of LEV systems
• Emergency procedures and incident reporting

Interactive Training and PPE Integration

Combine traditional training with videos, simulations, and live demonstrations. Reinforce the use of Personal Protective Equipment (PPE) such as masks and goggles where applicable.

Common Mistakes in Fume Extraction Implementation

Improper System Sizing
Installing an underpowered or oversized system leads to inefficiencies and higher operational costs. Always assess production volume and specific fume characteristics.

Neglecting Regular Testing and Servicing
Skipping LEV testing or delaying filter changes can result in non-compliance, system failure, and health hazards. Stick to a strict maintenance and testing calendar.

Innovations in Fume Extraction Technology

Smart Sensors and Automation
Modern extraction units feature air quality sensors, auto-on/off functionality, and IoT integration for real-time monitoring and remote control.

HEPA and Advanced Filtration Developments
Next-gen filters now offer improved particle capture rates, longer lifespans, and eco-friendly disposal options, enhancing both efficiency and sustainability.