Compact Pulse-Jet Filter with waste conveyor feeding woodwaste-burning heater.



Long straight runs of clip-together ducting add to the efficiency of the extraction system.


Precision machining and high quality vinyl-wrapping processes enable complex and creative designs to be achieved.



Dust extraction specialists Dust Control Systems have recently completed a major installation at the new premises of leading vinyl door manufacturer Crystal Doors. Moving from the site it had occupied since its formation in 1994 to larger more modern premises, Crystal Doors have increased their available factory floor space by more than 25%.

The new facility on a 1.2 acre site at Rochdale is dedicated to the production of bespoke vinyl-wrapped doors. “Unlike our old premises that had seen years of organic growth, the new facility presented us with a blank canvas”, says Managing Director, Richard Hagan. “We now have clear unrestricted space with the perfect floor plan of a 3x1 ratio. Everything has been planned to ensure the best possible use of space, resources and efficiency of production time.”

Crystal Doors was one of the first companies to invest in energy-saving dust extraction from DCS when an energy-efficient system was installed at their old premises towards the end of 2008.The most significant advantage of the system was its ability to provide precise extraction volumes only when required. This was achieved by utilising variable speed control and multiple, high-efficiency clean air fans, which operated ‘on-demand’. Operation was entirely automatic, with the extraction system’s power varying instantly as dampers opened and closed. This meant that the dust plant always ran at optimum efficiency keeping power usage to an absolute minimum.

Melvyn Bathgate, sales director at DCS, says: “When we designed the original system, we knew there was a strong likelihood that Crystal Doors would be re-locating to a new site in the future. The system was designed with this in mind – we employed ‘clip-together’ ducting runs, that could easily be re-used, and the capacity of the filter and fans were specified to cope with the anticipated increase in demand.”

With so many machines to be re-installed and commissioned, the move necessitated a two week production shut-down. DCS engineers were involved throughout the process, undertaking preparation work and installing extraction as machines were re-sited. Outdoors, the existing Reverse Jet Filter was re-installed together with a soft flight conveyor which feeds a woodwaste-burning system. The clear internal space also enabled DCS to install long straight ducting runs which has further contributed to the energy efficiency of the dust extraction system.

“We are delighted with move”, said Mr Hagan. “It satisfies our long awaited goal of streamlining production procedures, which means we can now offer our customers a 24-hour turnaround on bespoke door orders. DCS played a vital role in facilitating a smooth transition and completed a highly professional and very tidy installation. They looked after us every step of the way and went about their task with military-like precision.”



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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