December 2012/January 2013 - Low Resolution - PAWPRINT ...

PANELS & PANEL PROCESSING
Meeting extraction needs
DUST CONTROL Systems recently commissioned a new dust extraction plant which required
its engineers to devise an unusual, yet cost-effective scheme to best fulfil its
customers’ needs.
Integral Surface Designs Ltd, based in Skelmersdale, Lancashire, is a newly-established company
specialising in the manufacture of acrylic, vinyl-wrapped and MFC pvc-edged doors.
Over £750,000 has been invested in the new venture, which is led by Deralam Laminates Ltd,
a nationwide distributor of high pressure laminates, kitchen worktops and melamine-faced
products. Investment included the complete refurbishment and fit-out of a 12,000 ft 2 workshop
facility, along with the acquisition of an impressive array of advanced CNC-technology
nesting machines. The machinery was purchased with the aid of funding under the Government’s
Regional Growth Fund (RGF) and financed through NatWest and Lombard.
Heading up the new operation is Jeff Green, who has 27 years’ experience in the woodworking
industry, and considerable production management expertise in the manufacture
of vinyl doors and wrapped mouldings. The management team also includes Clare Hartley-
Montrone and Diane Williams; both of whom operate at director level, with responsibility for
sales of Integral’s extensive range of doors, panels and mouldings.
After finding suitable premises, Jeff Green project-managed the refurbishment and
sourced the necessary machines and equipment required to design and engineer a range of
high quality doors. Jeff was also determined from the outset that the facility should incorporate
a Waste-to-Energy system — utilising woodwaste generated during production as a
fuel to provide heat for the workshops. “I had no hesitation in contacting both Dust Control
Systems and Ranheat Engineering to put forward proposals for dealing with our MDF waste,”
says Jeff Green.
Left to right: Clare Hartley-Montrone, Jeff Green and Diane
Williams with one of Integral’s high-gloss doors.
Top of the class
MORE THAN 2,000 sheets of Norbord’s 11 mm Sterling OSB
3 have been incorporated into the timber wall panels of a
new grammar school in Kirkwall, Orkney.
The material, which is made at Norbord’s Inverness factory
from wood grown in sustainably-managed Scottish forests, was
supplied to design-build contractor, Morrison Construction, via
the Orkney branch of Jewson.
Morrison Construction is the main contractor on Orkney Islands
Council’s £58 million Schools Investment Programme.
This scheme, which got underway in March 2011 and will take
four years to complete, involves the construction of two new schools, a
new halls of residence and a swimming pool complex. The new Kirkwall
Grammar School building comprises three teaching wings connected by
an interlinking curved “street” which houses social and dining areas. A
new oval-shaped Orkney Arts Theatre will be integral to the building.
Sterling OSB was specified for the highly-insulated timber panels which
provide the main building envelope. They are combined with a variety of
external finishes including copper cladding, natural stone, render and facing
block. The building superstructure consists of a structural steel frame
DCS modular filter and hopper sit perfectly on
top of Ranheat’s 50 m 3 silo.
“I had experience of working with both these companies in the past and
they had always performed well.”
Working in close co-operation with Ranheat Engineering, DCS engineers
devised a filter system that could directly feed the silo of the new
300 kW heating system, without the need for costly transfer fans and conveying
systems. Melvyn Bathgate, sales director at DCS, explains: “We designed
the system whereby the filter unit could be mounted on a hopper
section and directly coupled to the 4 m diameter silo roof. In this way, extracted
wood dust and chips could be gravity fed straight into the hopper.
It meant that the whole system would only require just one main fan,
resulting in considerable cost savings for Integral Surface Designs.”
The completed structure, at almost 11 m high, incorporates a highefficiency
modular filter which is fitted with tubular ‘Super bag’ polyester
filter media, and is designed to handle an airflow capacity of 23,000 m 3 /hr.
The system provides extraction to a total of nine machines and has
enough capacity to accommodate additional machines in the future.
In addition to the installation of ducting runs throughout the facility,
DCS also supplied and installed a waste wood shredder and a dry back
spray booth. The robust Schuko shredder is capable of handling MDF,
chipboard and hardwood offcuts at a rate of 22-300 kg/hr, and the 4.4 m
wide galvanised spray booth incorporates two axial flow fans and disposable
double-layer paper-type filter media.
Dust Control Systems Ltd ● Tel 0800 040 7116
Email sales@dcslimited.co.uk ● www.dcslimited.co.uk
and its roof is aluminium standing seam system. “This is by far the largest
use of timber panels on any building I’ve seen on Orkney,” says Brian
Kynoch, manager of Jewson’s Kirkwall branch. “We supplied an initial order
for 1,476 sheets of OSB and started shipping in January 2012. We then received
an order for a further 738 sheets which were delivered in February.”
At Kirkwall Grammar School, the timber infill panels forming the external
envelope were largely complete by late April, having been started
only 12 weeks’ previously.
Norbord ● Tel 01786 812921 ● www.norbord.com
Page 16 Panel, Wood & Solid Surface December 2012/January 2013