DCS modular filter and hopper sit perfectly on top of Ranheat 50m3 silo.
L to R: Clare Hartley-Montrone, Jeff Green and Diane Williams with one of Integral’s high-gloss doors.
Schuko Shredder handles all types of wood-based off-cuts.




Dust Control Systems recently commissioned a new dust extraction plant which required its engineers to devise an unusual, yet cost-effective scheme to best fulfil its customers’ needs.

Integral Surface Designs Ltd, based in Skelmersdale, Lancashire, is a newly-established company specialising in the manufacture of acrylic, vinyl-wrapped, and MFC pvc-edged doors. Over £750,000 has been invested in the new venture which is led by Deralam Laminates Ltd, a nationwide distributor of High Pressure Laminates, Kitchen Worktops and Melamine-Faced Products. Investment included the complete refurbishment and fit-out of a 12,000 sq. ft. workshop facility, along with the acquisition of an impressive array of advanced CNC-technology nesting machines. The machinery was purchased with the aid of funding under the Government’s Regional Growth Fund (RGF) and financed through NatWest and Lombard.

Heading up the new operation is Jeff Green, who has 27 years experience in the woodworking industry, and considerable production management expertise in the manufacture of vinyl doors and wrapped mouldings. The management team also includes Clare Hartley-Montrone and Diane Williams; both of whom operate at director level, with responsibility for sales of Integral’s extensive range of doors, panels and mouldings.

After finding suitable premises, Jeff Green project-managed the refurbishment and sourced the necessary machines and equipment required to design and engineer a range of high quality doors. Jeff was also determined from the outset that the facility should incorporate a Waste-to-Energy system – utilising woodwaste generated during production as a fuel to provide heat for the workshops.

“I had no hesitation in contacting both Dust Control Systems and Ranheat Engineering to put forward proposals for dealing with our MDF waste”, says Jeff Green. “I had experience of working with both these companies in the past and they had always performed well.” Working in close co-operation with Ranheat Engineering, DCS engineers devised a filter system that could directly feed the silo of the new 300kW heating system, without the need for costly transfer fans and conveying systems. Melvyn Bathgate, sales director at DCS explains: “We designed the system whereby the filter unit could be mounted on a hopper section and directly coupled to the 4 metre diameter silo roof. In this way, extracted wood dust and chips could be gravity fed straight into the hopper. It meant that the whole system would only require just one main fan, resulting in considerable cost savings for Integral Surface Designs.”

The completed structure, at almost 11 metres high, incorporates a high-efficiency modular filter which is fitted with tubular ‘Superbag’ polyester filter media, and is designed to handle an airflow capacity of 23,000m3/hr. The system provides extraction to a total of nine machines and has enough capacity to accommodate additional machines in the future.

In addition to the installation of ducting runs throughout the facility, DCS also supplied and installed a waste wood Shredder and a Dry Back Spray Booth. The robust Schuko shredder is capable of handling MDF, chipboard and hardwood offcuts at a rate of 22-300kg/hr, and the 4.4m wide galvanised spray booth incorporates two axial flow fans and disposable double-layer paper-type filter media.


Dust Control Systems Ltd., Horace Waller VC Parade, Shawcross Business Park, Dewsbury, WF12 7RF
Telephone: +44 (0)1924 482500   E-mail:
Freephone: 0800 0407116

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