Compact DCS Pulse-Jet Filter installation at Crystal Doors


Extraction power varies as auto-dampers open and close.


Richard Hagan with one of the company’s latest designs of Shaker kitchen doors.



A leading vinyl door manufacturer has slashed energy bills for running its dust plant by investing in the latest ‘green technology’ dust extraction from Dust Control Systems Ltd.

Based in Middleton, Manchester, Crystal Doors are specialists in vinyl-wrapped doors and accessories, supplying to companies who offer bespoke manufactured solutions for any room in the home. In addition to continuous improvement of its manufacturing processes, the company has an ongoing commitment to responsible environmental practice. Recently this commitment, together with a drive to reduce energy costs, led Crystal Doors to invest in a new energy-efficient dust plant and a woodwaste-burning heating system.

The doors are manufactured in MDF using wood sourced from sustainable forests; boards are cut to size, machined to produce any design, and then finished with high quality printed vinyl. The new dust extraction system installed by DCS comprises an externally sited Reverse Jet Filter, designed to operate under negative pressure and handle air volumes of 20,000 m3/hr. The compact, high-efficiency filter deals with MDF dust from ten high-performance woodworking machines, three beam saws and a hogger that granulates offcuts. Waste is discharged, pressure-free, from the filter via a rotary valve to a soft flight conveyor which in turn feeds direct to a fuel storage silo.

Melvyn Bathgate, sales director at DCS, says: “The most significant advantage of the new extraction system is its ability to provide precise extraction volumes only when they’re needed. This is achieved by utilising variable speed control and multiple high-efficiency clean air fans which operate ‘on-demand’ from each of 14 machines. Operation is entirely automatic, with the extraction system’s power varying instantly as dampers open and close. This means that the dust plant always runs at optimum efficiency and keeps power usage to an absolute minimum.”

Dust Control Systems replaced three existing dust extractors and installed the new plant, complete with clip-together ducting runs and automatic damper systems, without interruption to Crystal Doors’ day-to-day production. Managing Director, Richard Hagan commented: “We are delighted with the new extraction system; our old equipment employed fixed speed fans, running constantly at over 100kW for 10 hours a day, wasting vast amounts of valuable energy. In contrast, the new extractor uses only 24kW to 40kW, operates fully automatically, and gives us optimum extraction volume, just when we need it.”

Crystal Doors has certainly put its woodwaste to positive use – 95% is now recycled. The 20,000 sq. ft. manufacturing facility is fully heated in winter, without the need for other heat sources, whilst waste disposal and energy costs have been dramatically reduced. This new ‘green technology’ extraction, with the added benefit of a genuine payback on investment, adds up to both environmental and commercial sense.



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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