Introduction
Compass Windows & Doors, based in Londonderry, stands as Ireland’s premier manufacturer of Timber, Aluminium, PVCu, and Alu-Clad windows and doors, catering to both residential and commercial sectors. Established in 1977, the company has seen significant growth and development over the past four decades, driven by substantial investments in both their workforce and advanced machinery.
One notable development includes the acquisition of two state-of-the-art machines from SCM, a leading producer of woodworking equipment. The new CNC Router and complex Windowflex machine, are capable of performing all necessary operations for producing window frames from solid timber.
With the integration of these machines, Compass Windows & Doors recognised the need to re-evaluate their dust extraction systems. They enlisted dust extraction specialists, Dust Control Environmental (DCE) Ltd. to design, manufacture and install a compliant dust extraction system in line with health and safety and environmental standards, maintaining a healthy workspace.
Project Requirements
- Additional new machinery, meant the current cyclone dust collectors at Compass were now undersized, no longer providing effective and compliant dust extraction. A more efficient system was required.
- Compliance needed to align with the latest EPA (Environmental Protection Law), mandating improved control of pollution from certain industrial processes. This includes managing dust that can be harmful to health or a nuisance to the public.
- A requirement to manage energy consumption and sustainability goals.
- Safe operation of the extraction equipment in a combustible atmosphere was essential.
- The machinery commissioning was scheduled to take place before the new tailored dust extraction system from DCE was ready. This was to minimise downtime and gain a quick return to production.
- Machines already on site needed to be integrated into the new extraction system.
- Removal of the old cyclone units from the site would be necessary.
How DCE met the Requirements
Dust Control Environmental set about planning the new dust extraction and installation with as little interruption as possible to the production at Compass.
In order for Compass to enable the commissioning of the CNC and Windowflex to the required timescale, DCE loaned a stock ATEX dust extraction filter at short notice. The machines were therefore productive whilst waiting for the permanent extraction filter.
Enhanced dust control was ultimately provided in the form of A DCE Envirojet W – Series. This negative pressure filter unit provides high-performance extraction. Manufactured with ATEX adaptions ensures safe operation in this explosive risk environment.
The Envirojet W has an innovation E-performance panel to monitor machine use and tailor the cascading fan function to operational requirements providing energy savings of up to 50%. The incorporation of a waste pre-separation chamber and the use of oval filter bags extends the lifecycle of the filter media.
Whilst installing the Envirojet W –Series, along with control panels and ducting, DCE were able to link into the system’s older machines already in operation. The removal of the two old cyclone filters was carried out, free of charge, by DCE fitters whilst on site.
The Benefits
Dust Control Environmental delivered a comprehensive “one stop service” from start to finish. Their expertise in design, manufacture, and installation (including ducting, monitoring, and controls) ensured a seamless and complete project.
With the installation of the DCE Envirojet W –Series, Compass will experience highly proficient dust- extraction throughout processing areas, providing healthy, clean air for the workforce. Equipment and machinery will also be protected from detrimental dust ingress, saving time on maintenance and housing keeping.
The E-performance monitoring will regulate the speed and number of fans required to facilitate optimum dust extraction in line with the number of machines operational. By only activating what is necessary, a year on year saving in energy will be made, assisting Compass to achieve environmental goals. The reduction in filter bag changes, with less going to land waste, provides another financial and environmental win.
Production downtime was reduced greatly with the loan, from DCE, of the ATEX filter resulting in a smoother operating transition from the old to the new dust extraction system.
Conformity to EPA will be achieved with the advanced dust extraction supplied by the Envirojet W-Series dust collector with the ATEX modifications providing the assurance of safe operation.
Client Feedback
Compass Windows & Doors Managing Director Michael O’Kane said of the project “The management team at Compass are extremely pleased to have appointed Dust Control Environmental Ltd. to carry out a complete and comprehensive renewal of their dust extraction system in 2024.
“We found the staff at DCE to be most professional, informed, helpful and accommodating throughout.
“From advice on the initial design, through to installation and commissioning the entirely new extraction system, DCE surpassed our expectations.
“For example, to avoid any interruption to our production, DCE proposed and installed a temporary dust extraction system whilst the new system was being installed and commissioned.
“Most importantly, the overall project was delivered successfully, both on time and on budget.
“We are delighted with the performance of our newly installed Dust Extraction System and would have absolutely no hesitation in recommending Martin (Gill), Steve (Bukowski) and their team to any prospective clients.”
