Dynamic real-time graphics allows the operator to monitor the extraction plant’s operation.


The impressive new DCS Dust Extraction Plant at The Explorer Group.



Dust Control Systems beat off all its major competitors to secure an order to supply leading caravan and motorhome manufacturer, The Explorer Group, with a new dust extraction plant.

Based at a large modern manufacturing facility in Consett, County Durham, Explorer employs over 400 people and produces around 5,500 caravans and motorhomes annually. The company had decided to replace their existing dust plant with a more efficient and up to date system which would fully comply with the ATEX directive.

The new extraction system supplied by DCS comprises two RF type reverse jet filter units, with a total airflow capacity of 170,000m3/hr, to extract heavy dust-laden air from over 60 woodworking machines. Each filter unit is fitted with oval-shaped Dura-LifeTM tubular filter bags. The advanced technology media used in Dura-Life bags means filter bags last two-to-three times longer than standard polyester bags, thereby significantly reducing replacement bag costs. A Delta-P Controller optimises pulsejet cleaning on-line allowing 24-hour operation. Not only does this minimise air consumption but, as each row of bags is only cleaned when necessary, the life of the bags is further extended. Collected woodwaste is discharged from the hopper in the base of each filter unit via rotary valve into a closed loop conveyor system that feeds a high efficiency cyclone. The woodwaste then passes into a silo for subsequent use as heater fuel.

The new dust plant has a relatively small footprint and comfortably fits into limited space between the factory wall and the site’s service road. With an outdoor location it was important to keep noise levels from the system to an absolute minimum - this was achieved by housing the four 75kW extraction fans within acoustic enclosures. DCS also installed 850 metres of ducting runs throughout Explorer’s workshops incorporating spark detection and continuous monitoring.

Ken Stonley, Production Engineer at Explorer, says: “Before placing our order with DCS we considered proposals from a number of leading companies. Because of the very restricted area in which the filter had to be located we required an extremely compact design of filter. Also, with a ‘lean manufacturing’ strategy in place at Explorer, it was imperative that we had a system that would require little or no maintenance and would be able to run continuously at the same high level of performance”.

Mr Stonley adds, “The DCS proposal fully satisfied our requirements and their attention to detail during the projects stage was a contributing factor in our decision to appoint the contract to them. The supply and installation of the extraction plant was achieved efficiently with minimal disruption to the production process. We now have an extremely efficient dust plant that does everything DCS claimed it would do”.


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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