Introduction
Kitchen components manufacturer, Carysil UK, are renowned for premium products including sinks, faucets, built-in appliances and kitchen work surfaces. Operating across more than 58 countries, Carysil UK has a reputation for innovation, quality and manufacturing excellence.
At its Derbyshire facilities, Carysil UK manufactures a range of high-quality solid surface worktops. To improve dust extraction efficiency while maintaining high standards for compliance and product quality, the company appointed dust extraction specialists Dust Control Environmental (DCE) Ltd. to design and deliver a high-performance system capable of managing the operational dust loads.
Project Requirements
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DCE, after a detailed site survey, ascertained that the current extraction and fan systems would require complete replacement and upgrade to ensure safe handling and efficient control of process dust including resin, wood dust and shavings.
The system would need to be able to handle a mixture of fine to medium dust and provide a total extraction rate of 34,330 m3/hr. Importantly, as resin and wood dust are classified as explosive, ATEX options are imperative for the safe operation of the new dust collector.
Extraction is required to operate from all process points with an emphasis on improving both operational reliability and reducing energy use.
How DCE met the Requirements
Tailored to Carysil UK’s specific requirements, Dust Control Environmental manufactured and installed their Envirojet Reverse Jet Bag Filter. Standing externally to the premises, this high-performing dust collector provides efficient collection of the different dust types and loads. The system offers true 24/7 performance with the reverse jet cleaning system which does not require system shutdown.
The Envirojet incorporates a floor mounted ATEX fan and ATEX propagation valve. Return air technology was integrated with the addition of a HEPA H13 filtration bank and 50% air return ducting.
The Benefits
Now installed, the Envirojet delivers the following benefits for Carysil UK, supporting compliance while demonstrating the company’s commitment to product quality and workforce safety.
Improved workforce protection is achieved through consistent, high-performance extraction that captures particulates at source across all operational points, providing a total extraction rate of 34,330m3/Hr.
Essential compliance and safety are supported by meeting COSHH and workplace air quality requirements. ATEX design features also ensure safe operation and reduce the risk of serious incidents.
Reduced energy consumption is supported by the 50% return air system, which uses HEPA filtration to clean air for recirculation back into the facility. Maintaining ambient air temperatures during operation can help lower heating costs. This can contribute to Carysil UK achieving their environmental goals.
Minimised production downtime is achieved through reverse jet cleaning technology, which enables the extraction system to clean continuously whilst in operation.
Client Feedback
Carysil UK Production Team Manager, Tony Smith, said “Creating high-quality products starts with taking care of our people and our operations. Prioritising our team’s health, safety and working environment is paramount to everything we do. Partnering with DCE gave us total confidence that our facilities remain safe, fully compliant and performing at their absolute best.”
