DCS wrap it up at Crystal Doors

Posted by on 18 Jul 2017

Dust Control Systems Ltd (DCS) has recently completed installation work on a substantial new dust extraction system for Crystal Doors – one of the UK’s leading manufacturers of vinyl-wrapped doors.

From its 30,000 sq. ft. manufacturing facility, just off the M62 on the outskirts of Rochdale, Crystal Doors’ 34-strong workforce is dedicated to the production of bespoke vinyl-wrapped doors and accessories for kitchens, bedrooms and bathrooms, and manufactures over 200,000 pieces a year. The company offers a vast selection of designs, foils and materials, and has the capability of profiling doors up to 3 metres in length, as well as custom-printed, curved and 3-dimensional panels. More recently, the installation of high-tech robotic paint and glue spraying equipment, which utilises 3D laser technology, has increased production speeds and ensures a perfect finish for painted doors.

Established in 1994, by Managing Director Richard Hagan, Crystal Doors has earned a distinguished reputation for its environmental quality and efficiency achievements, with year on year improvements in environmental performance indicators, and has gained recognition from industry, business and environmental organisations, including being named Business of the Year 2015 in the Rochdale Business Awards. Over 99% of all waste is recycled, including collection and onsite storage of wood waste to fuel a biomass boiler; providing heat and hot water for the factory and offices. Since re-locating to Rochdale 6 years ago, energy consumption and electricity costs for the building have been reduced by replacing over 90% of the lighting with LED units, or high efficiency alternatives.

However, in common with most production units, dust and fume extraction is the biggest single energy consumer and, although Crystal Doors had previously invested in high-efficiency extraction equipment from DCS, the existing filter unit pre-dated the relocation to Rochdale. DCS Sales Director, Melvyn Bathgate, explains: “With the increased levels of production that Crystal Doors has achieved through investments in new equipment, the 20,000m3/hr capacity filter was working close to its limit – even with our Ecogate energy-saving technology installed, fans were often running flat out to cope with demand.”

“DCS and Crystal Doors go back over 20 years” says Richard Hagan, “and I had no hesitation in asking Melvyn to put forward a proposal for a new system which would fulfil both our current and future needs. Also, our factory is situated alongside Rochdale Canal – which is designated as a Site of Special Scientific Interest by Natural England – so, as well as being energy-efficient and ‘future proof’ in terms of its capacity, it’s very important that the system design and engineering quality safeguards against the risk of MDF dust ending up in the canal.”

Ecogate optimised extraction systems automatically adjust power output to the fans, in real time, to match the exact requirements of the manufacturing process, resulting in significant energy and cost savings – at Crystal Doors, early indications show that the new system is running at almost half the cost of the previous installation.
Richard Hagan concludes: “As always, the service provided by DCS was exemplary, and we now have the most efficient extraction system possible for our business, with capacity to spare and a life expectancy in excess of 20 years.”