Concept Smoke Systems Ltd - Celebrates 60 Years of Artificial Smoke
Not always smoke…
From its origins as Concept Engineering Ltd, the company quickly rose to prominence following a merger with IES Projects Ltd. This exciting collaboration saw the company contribute to some of the most iconic moments in film and television history.
Highlights included:
In 1976, Concept’s team constructed the only full-size X-Wing fighter for Star Wars, at a cost of £27,500.00. Even though the final battle involves nearly two dozen starfighters inside the Death Star trenches, none are full sized. According to the special effects designer, John Stears, the only full sized starfighter in the movie is the one we see in Yavin 4’s base hangar. (read about it here).
One of the most iconic stunts in cinematic history was brought to life by the Concept team, who engineered the dramatic launch of the white Lotus Esprit off a jetty in The Spy Who Loved Me (1977). In this scene, Roger Moore, at the wheel of the sleek Lotus Esprit, jumps off the jetty and the car seamlessly transforms into a submersible. Behind the cinematic magic was the ingenuity and precision engineering of the Concept team, who developed and executed the complex mechanism that launched the car into the water, creating one of the most memorable stunts in Bond history.
Another standout achievement was the construction of a fully functional replica of the Vickers FB5 Gunbus biplane for the 1976 film Shout at the Devil. Recreating this early WWI-era aircraft was no small feat, it required not only historical accuracy but also full airworthiness. The Concept team rose to the challenge, engineering a replica that didn’t just look authentic but was capable of flight. The aircraft was successfully test-flown in the UK at Concept’s original HQ on White Waltham Airfield, before being carefully shipped to South Africa for use in the film’s aerial sequences.
Back to what we do best
As the company stepped back from film work, it concentrated its efforts on becoming a global authority in artificial smoke. Today, Concept is recognised as the world’s longest-standing smoke machine manufacturer, offering a diverse range of systems—from portable, battery-powered generators to complex, integrated industrial units and specialising in bespoke OEM development and manufacturing, creating application specific solutions for our customers.
At the heart of Concept’s mains driven smoke generators lies their famous heat exchanger technology, engineered for optimum performance, reliability, and serviceability. These high-mass, precision machined heat exchangers offer unparalleled performance and as they are fully serviceable assemblies, Concept guarantee them for life.
It’s thanks to this heat exchanger technology that helps Concept’s smoke generators to produce an effect with the smallest and most consistent particle size possible (just 0.2–0.3 µm mmd). Smaller particle size typically means; less fluid to achieve the same visual obscuration, lower running costs, safer smoke, slower particle settling velocity and cleaner smoke.
If you take the below (right) image as an example, if the particle on the right was a 0.2 micron Concept smoke particle, the one on the left would be just over 1.5 micron diameter. That’s a typical particle size of most generic smoke systems available, typically producing particles 1–5 micron diameter using cast or platen type heat exchangers.
For more information on particle size, please visit Smoke Particle Size & Settling Velocities
Early machines
Click on image above to download the Concept Genie MKV brochure.
Some of the earliest and most iconic smoke generators manufactured by Concept include the Concept Genie MKV and the Concept Comet.
The Concept Genie MKV, developed in the early 1970s, quickly became a favourite among professionals requiring a high-output, reliable smoke generator. Designed for versatility, the MKV saw widespread use across film and television special effects, fire brigade training exercises, and even as part of multi-million-pound aircraft flight simulators—a testament to its performance and build quality.
Although production ceased in 1995, the Genie MKV’s legacy endures. Dozens of units remain operational to this day, particularly in Japan, where the machine has a strong and loyal following. Its continued use over decades highlights the MKV’s robust engineering, simple operation, and lasting impact in the field of artificial smoke generation.
Click on image above to download the Concept Genie MKV operating instructions.
Today’s version of the Genie MK5 is Concept’s ViCount / Vulcan smoke generators which are considered among the most capable smoke generators on the planet. Concept produce different variants of this range to suit specific industry needs.
Industrial Range
Optimised for maximum smoke output, commonly used for military or emergency services for training. The smoke is also temperature resistant up to ~ 200˚C making it the first choice for hot smoke testing & hot fire training facilities.
Hazer Range
With a class leading particle size and unbeatable persistence from the resulting effect it’s no wonder the ViCount Hazer is one of the most popular systems by professionals in AV and SFX for creating stunning atmospherics.
Wind Tunnel Range
The ViCount WT is a specialist version, designed for wind tunnels and aerodynamic studies. It produces dense, uniform smoke ideal for flow visualisation, including PIV and LDV. With precise control, and reliable performance, it’s perfect for research, universities, and test labs needing clear, consistent smoke for airflow and turbulence testing.
Cleanroom Range
The VC Aero range are essential tools for challenging HEPA filters to ensure their efficiency and integrity in critical environments. They produce a fine, consistent aerosol of known particle size and concentration, mimicking contaminants that the filter is designed to capture. This allows for accurate testing of the filter’s performance under real-world conditions, verifying that it meets stringent standards for particle retention
Click on image above to download the Comet smoke system brochure.
The Comet smoke system was developed in the late 1970’s and manufactured until 1992. It was a pioneering product using pressurised smoke canisters rather than a conventional pump or CO2 / N2 supply to propel fluid through the system and produce smoke.
In the 1980’s it was recognised by the Bundesmarine (German Navy) that the Comet would be a excellent tool for to complement their fire training.
Click on image above to download the Comet smoke system operating instructions.
This paved the way for the Colt 4 which was introduced in 1987 and remains to this day one of Concept’s bestselling products.
Despite its compact size the Colt 4 can produce huge volumes of smoke. The unit, once pre-heated (5 minutes) can then be unplugged and used off power using retained energy (heat) from the high-mass heat exchanger.
The Colt 4 is arguably one of the toughest smoke generators on the market – designed for the harshest of environments. Look back to 2012, where we tried to destroy a unit. First throwing it in a field, then in a carpark, then dropping it from a mezzanine – it still worked!
In 2007 Concept were awarded the contract to exclusively supply the Royal Navy with Colt 4 Turbo for shipboard fire training. To this day, every Royal Navy Vessel / Submarine has this system on board.
The Colt 4 Turbo was recently showcased on the BBC Documentary HMS Queen Elizabeth – The Warship: Tour of Duty.
Brochure Archive
Click on the brochures to view
Security Smoke
Among Concept’s many pioneering innovations, one of the most significant came in 1975, when the company designed, manufactured, and installed the world’s first security smoke system. Commissioned by Johnson Matthey to protect gold bullion stored in high-security vaults, the project led to the development of both 12V mobile systems for their vehicle fleet and mains-powered systems for static installations – a groundbreaking leap in proactive asset protection.
In 1994, Concept began working closely with Security Pyrotechnics Ltd, a collaboration that evolved into the formation of Concept Smoke Screen Ltd -now a dedicated sister company to Concept Smoke Systems Ltd. This marked the beginning of a specialised focus on intruder deterrence and security defence using artificial smoke.
Over the years, Concept Smoke Screen has delivered a number of high-profile and mission-critical solutions. Notably, in 2005, the company collaborated with the United States Air Force (USAF) to develop a system designed to protect nuclear missile silos. In the rare event of a breach, the smoke screen rendered visibility and navigation near-impossible – dramatically enhancing the security of these high-value military assets.
In 2010, another major milestone was reached through a partnership with G4S, resulting in the development of a portable, rapidly deployable smoke screen system for use by their personnel during ATM refills. Designed to be activated instantly in the event of a threat, these units are still used daily – protecting staff, safeguarding property, and preventing the loss of millions of pounds over the past decade.
From gold vaults to global defence, Concept Smoke Screen Ltd has continued to lead the way in security smoke innovation, earning its place as a trusted name in threat deterrence and tactical protection across sectors and continents.
Visit www.smoke-screen.co.uk or click the image below for their latest brochure.
Other amazing jobs that left a lasting impression
In 1994, one of the earliest large-scale hot smoke tests was carried out at Brussels Airport, using a bank of six ViCount smoke generators to create a highly visible, thermally buoyant smoke. The success of these tests played a key role in shaping international standards for hot smoke testing and remains a benchmark for performance and reliability. To this day, the results are still referenced in computational fluid dynamics (CFD) models used for the design and validation of modern smoke control systems worldwide.
Concept have been proud to support a wide range of high-profile projects and landmark events with but one particularly notable collaboration was with Artem Special Effects for the London 2012 Olympic Games Opening Ceremony – a globally watched spectacle.
Specialist machines derived from the Spirit 900 and Colt 3 were designed and used to create the atmospheric effects that bellowed out of the seven huge (up to 30mtr) chimneys around the stadium.
In 2018 Concept partnered with Concept partnered with renowned special effects supervisor Chris Corbould and luxury automaker Aston Martin to develop a bespoke smoke screen system for the limited-edition 007 Goldfinger DB5 Continuation cars. This collaboration brought one of James Bond’s most iconic gadgets to life, seamlessly integrating movie magic into a fully drivable vehicle. Only 25 DB5 were manufactured (each with two smoke systems on board) with a price tag in excess of £3 million.
In 2024 Concept worked with partners Lumina Visual Productions and RAMUS in Australia on K’gari, formerly Fraser Island on a project called Illumina – Return to Sky. Concept produced a number of bespoke Vulcan Hazers to fit inside IP rated enclosures. The machines we’re fitted with an automatic refilling station to minimise daily maintenance and DMX controlled proportional regulators for optimum controllability. The resulting haze creates a stunning atmospheric effect that compliments RAMUS’s amazing design and work.
For more news and highlights, visit Latest News – Concept Smoke Systems.
Want to talk smoke
Meeting in Las Vegas at LDI 2025 – We’re excited to share that Concept Smoke Systems will be attending LDI—Live Design International—in Las Vegas this December! LDI is the premier gathering for live event design and technology professionals, drawing over 16,000 attendees and more than 300 exhibitors showcasing cutting-edge gear, lighting, special effects, staging, and more It’s the perfect setting for inspiration, collaboration, and innovation.
We’d love to catch up and talk more smoke—whether you’re interested in how our latest systems can elevate your productions, curious about past projects, or simply want to share stories. Let’s meet!
Visit Us at Home – Concept Smoke Systems are based in Maidenhead, and we’re always happy to welcome guests. Whether you’re exploring new opportunities or revisiting a vintage Concept machine, we’d love to host you.
A final word
The company’s continued success is a testament not only to its leadership but also to the strength and dedication of the team behind it. Trevor Dunnington, who joined the business in 1981, has served as Managing and Technical Director since 1992, playing a central role in shaping Concept’s evolution. Under his guidance, the company has embraced continuous technical innovation, expanded its global reach, and earned a reputation for engineering excellence, trusted partnerships, and unwavering reliability.
But these achievements are not the work of one individual—they reflect the commitment of an exceptional team, many of whom have been with the company for over a decade, with several proudly serving for 20 years or more. This rare continuity has created a culture of deep expertise, loyalty, and shared purpose that spans every department—from design and production to customer support and global distribution. The team’s collaborative spirit and commitment to quality, service, and innovation have enabled Concept not just to adapt to change, but to lead the industry forward.
As Concept Smoke Systems Ltd celebrates its 60-year milestone, it remains firmly focused on the future. With a diverse range of technologies trusted in industrial testing, fire training, military exercises, security applications, and special effects, the company is poised to meet the evolving demands of its customers for decades to come.
We want to extend our heartfelt thanks to our loyal customers, distributors, and partners around the world. Your trust, collaboration, and feedback have been instrumental in transforming bold ideas into the world-class smoke systems Concept is known for today. From early prototypes built in modest workshops to cutting-edge systems operating in some of the most critical environments on the planet—this journey has been shaped by you.
Here’s to the next 60 years of smoke, science, and success. If you have questions, stories to share, or are looking for support with a vintage Concept machine, we’d love to hear from you—get in touch and be part of the next chapter in our story.
Prepared by:
Andrew Dunnington | Operations Director | Concept Smoke Systems Ltd | andy@conceptsmoke.com
