Open Bag Filters

Modular Bag Filters

Through Flow Filters

Rotary Valve / Silo Filters

Chain Filters

Cyclo-Filters

Spray Booths

Air Input Systems

Chippers

Solid Fuel Heating

Storage Silo’s

Case Histories : 1

New DPS Extraction System -
On time and on Budget - again

David Salisbury Conservatories is a major force in the hardwood conservatory market. From humble beginnings in 1984, the company has dramatically grown, reaching a sales turnover of £4 million in 2000 and it is still expanding rapidly. The company produces top-of-the-range timber conservatories and specialises supplying these to listed buildings and country properties. Increased sales and the consequent demand for higher production meant that they had outgrown the capacity of their original premises and needed to relocate.

Producing high value conservatories meant that end product quality was important, thus controlling the workplace environment is a significant factor.

Additionally, David Salisbury Conservatories wished to have a factory that was safe, pleasant to work in and met H.S.E. regulations. The move to new premises was therefore seen as an opportunity to plan their facilities to maximise the production flow and also, as part of the investment, replace and upgrade its woodwaste extraction system.

A Flexible Design
‘Moving into new premises presented us with a number of opportunities and also problems,’ commented David Salisbury (the company's owner). ‘one of which was choosing a supplier for our extraction system. This had to be designed to be flexible enough to meet our current needs yet be easily expandable for our requirements in the future. We assessed the capabilities of a number of extraction system specialists. On the face of it many seemed capable enough but most only seemed willing to give us their angle on what we needed. What impressed me about Dust Pollution Systems (DPS), was their commitment to supplying, not just what they felt would be appropriate but, more importantly, what we really needed. They seemed keen to enter into a constructive dialogue. This entailed DPS preparing and submitting a number of schemes, which gave us the opportunity to assess each on its merit. Although this obviously took time, this DPS approach was impressive. We've got what we really needed not what a supplier was prepared to provide.’

Minimal Disruption to Production
Whilst with any large-scale investment initial cost is an important factor, of equal importance is the installation process and this impressed David Salisbury. He commented, ‘We had to move our entire manufacturing plant so it was important that our production losses were minimised, especially as we had existing orders to fulfil and have our own timescales to meet. So we needed the assurance that we could continue manufacturing to meet our orders.’

David Salisbury comments, ‘To meet this crucial requirement DPS drew up a work schedule that enabled them to complete the external work and basic ducting system first. This meant that as each machine was installed it could be easily and quickly connected to the new extraction system. The installation of our first stage conversion machines took five days to complete. This was a critical stage as it enabled us to produce our core profiles. During the second week our secondary equipment (e.g. spindles, finishing and wrapping facilities) was installed and connected where appropriate. Essentially, therefore, by the end of the second week, we were back in full production.’

They delivered everything that they promised≠
Said David Salisbury, ‘With any major move there is always an element of uncertainty, there's a lot going on and potentially a lot that can go wrong. In relation to the extraction system at least, the entire installation process by

DPS was exemplary. They delivered everything that was promised on time and did not delay the commissioning of our new factory. We were very impressed with the competence of the DPS fitters and the quality and efficiency of our new extraction system. From order to delivery, and installation, DPS were on schedule. This was important because we needed to be up and running quickly.’

The new DPS extraction system at David Salisbury Conservatories comprises of DPS modular chain filters, which can be expanded very easily expanded by simply connecting additional filters at either side. The machines are split between four extraction systems with extract produced by fans ranging from 25 to 40hp. This provides the flexibility to match very precisely the level of production being undertaken at any time. This reduces power consumption and running cost. There is a 15hp closed loop transfer system from the chain filter to facilitate waste transfer to two trailer containers for disposal.

To lower factory running costs, the DPS system has a full air return (with secondary filtration). This means that during the winter warm clean air can be returned to the factory, not only reducing heating costs but also minimising dust contamination - producing a clean efficient work environment.

During the summer air can be dumped so that the factory can be kept cool. To counter the risk of flash ignition all return air ducts have been fitted with fire dampers, which are linked to the control panel so that the entire system will automatically shut down in the event of a fire.

Summing up David Salisbury, stated, ‘The new extraction system was, on reflection, the least painful part of the overall move. I would say that DPS were prepared to do everything they could to ensure that our schedule was met. Nothing was too much trouble. In relation to the final connection, for example, although we employed are own electrician, it became obvious that there was too much to cope with and in order the assist us, DPS bought in their own electrician, ensuring that we were able to keep to a very tight schedule. It is very reassuring that even in these days you can still find outstanding customer commitment.’