Dust Control Systems’ engineering skills, and their ability to successfully complete contracts within an extremely tight schedule, were well and truly put to the test on a recent project for Kingspan Access Floors.
As part of a move to further automate panel processing at their Hull based manufacturing centre, leading raised access flooring manufacturer, Kingspan Access Floors Ltd., decided to relocate a complete edge-banding line from one side of the factory to the other, bringing two processing lines together. The plan was to complete the task over Christmas shut-down and have the two lines fully operational in time for the first day back after the holiday. Apart from all the logistical problems associated with physically moving all the machines in the line, there was also the need to have an effective dust extraction system installed and fully working from day one.
Steve Williams, Engineering Manager at the Kingspan site explains: “The issue of Dust Extraction is a major consideration in a project of this kind so we called in DCS, who supplied our existing system and are contracted to provide maintenance on our extraction equipment. They were required to come up with proposals for an effective long term scheme along with guarantees on completion times.”
The solution provided by Dust Control Systems involved the removal of one redundant chain filter and the upgrading of one of two other existing modular chain filters to increase its capacity. This necessitated the introduction of a new 75kW high-efficiency fanset with sound enclosure and changes to the waste transfer system. The main fanset serving the other filter unit was up-rated and modifications were made to the extraction system’s control panel. However, it was inside the facility that the changes were more extensive. A complete new network of clip-together ducting was installed including a pneumatic diverter valve, which allows Kingspan to readily switch extraction from one line to the other.
DCS Director, Melvyn Bathgate says: “We were confident we had the right solution in terms of equipment but it was vital that every aspect of the project was carefully planned and managed to achieve installation within the timescale. The time-contingent programme meant that our engineers had just 9 days over the holiday shut-down to complete the work and, of course, they had to work alongside other trades throughout. Thanks to the know-how, teamwork and dedication of our engineers all the equipment was installed and fully working in time for start up after the holidays.”
Mr Williams has nothing but praise for the performance of Dust Control Systems. “DCS did everything they said they would and we were immensely impressed with the standard of work and the level of service, particularly when you consider that it was achieved over the festive season.”