Dust extraction has traditionally been viewed as little more than a necessary overhead. As long as it kept factories compliant and employees safe, it rarely attracted much attention. But with electricity prices remaining high and manufacturers looking more closely at operating costs, that attitude is beginning to change.
For many manufacturers, the extraction system is one of the largest consumers of electricity on site. Improving its efficiency can therefore have a significant impact on operating costs without affecting production output.
That shift in thinking is something Ray Townley, Business Development Manager at Extractly, is seeing first-hand.
"A big part of what we do at Extractly is to make sure that what we're selling is not actually just a product, but a solution to their problems," says Ray.
For Ray, that means looking well beyond the initial installation. Factory layouts change, machinery is relocated and production demands evolve over time, meaning extraction systems also need to adapt. Alongside meeting the requirements of the Control of Substances Hazardous to Health (COSHH) Regulations and Local Exhaust Ventilation (LEV), maintaining effective extraction helps protect employees, support production and prevent small issues becoming expensive problems.
"What's important for Extractly is that we do things properly. We don't do them and say, 'That'll do,' and run off. We make sure it's safe, compliant and would easily pass the LEV and COSHH regulations associated with dust extraction."
Rather than spending his time reacting to problems after they occur, Ray prefers to help customers prevent them altogether.
"I'm not here to try and put fires out following problems," he explains. "I'm here to make sure the fires don't even start."
When issues do arise, he believes customers value speed and honesty just as much as technical expertise.
"If I get a whisper that something might have gone wrong, then I'll get in my car and go and see them," says Ray. "I'll explain what happened, why it happened and make sure it doesn't happen again."
One area where customers are increasingly looking for advice is demand-controlled dust extraction through EcoGate technology, which Extractly supplies across the UK and Ireland.
Conventional extraction systems are often designed for maximum demand, with large central fans running continuously whether one machine or twenty are producing dust. EcoGate takes a different approach, automatically adjusting airflow by opening and closing blast gates while varying fan speed to match production in real time.
The potential energy savings are based on a simple engineering principle.
"EcoGate is an energy-saving system that works on fans whether they're pushing air or pulling air, and they're subject to the cubic law," explains Ray.
"If you slow the fan down by 10%, it actually reduces the amount of energy absorbed by 27%. Two drops of 10% would equal around a 50% saving in electricity on that fan."
Running fans only as hard as necessary can also reduce wear on filters and mechanical components while creating a quieter working environment. However, Ray believes the biggest change is in the way manufacturers think about extraction.
"We will not put these big fans on and let them run all day. It's like putting your foot down on a car's accelerator and using your brake to slow down instead of taking your foot off the accelerator."
With energy costs remaining significantly higher than they were only a few years ago, more manufacturers are judging investments on lifetime operating costs rather than purchase price alone.
Ray recalls one customer whose investment delivered a faster return than expected.
"We sold the job with a return on investment of 24 months," he says. "He rang me after 14 months because he'd monitored the electricity bills. That was the point he'd already got his money back."
Extractly also takes a cautious approach when calculating potential savings.
"We always estimate a little bit high and deliver a little bit low. If we say the return on investment is two years, it's usually going to be 20 months or less."
Although woodworking remains the company's core market, Ray believes the same engineering principles apply across a wide range of industries, from concrete processing to petrochemical fume extraction.
Looking ahead, he expects demand-controlled extraction to become increasingly common as manufacturers continue searching for practical ways to improve efficiency.
"Energy isn't going to get cheaper," he says. "There's no reason to have a fan big enough to extract from every machine in the factory all day long. Put gates on the machines and only allow extraction where dust is actually being produced."
As manufacturers continue investing in more efficient machinery and automated production, utilities are coming under greater scrutiny. Dust extraction is no longer being viewed simply as a compliance requirement, but as another opportunity to reduce operating costs and improve the overall efficiency of the factory.
For more information visit www.extractly.co.uk.
Frequently Asked Questions
How can dust extraction systems reduce energy costs?
Dust extraction systems can reduce energy costs by adjusting airflow and fan speed according to actual production demand. Instead of running a large extraction fan continuously at full capacity, demand-controlled systems can reduce airflow when fewer machines are operating, helping minimise unnecessary electricity consumption.
What is demand-controlled dust extraction?
Demand-controlled dust extraction automatically adjusts the extraction system according to the number of machines operating and the amount of dust being produced. Blast gates control which machines are connected to the extraction system, while variable fan speed allows the system to provide only the airflow required at any given time.
How does EcoGate save energy on dust extraction systems?
EcoGate helps reduce energy consumption by automatically opening and closing blast gates and adjusting fan speed according to production requirements. This means the extraction system does not need to operate at maximum capacity when only a small number of machines are being used.
What is the cubic law in dust extraction?
The cubic law describes the relationship between fan speed and energy consumption. When fan speed is reduced, power consumption can fall significantly. This means even relatively small reductions in fan speed can result in substantial energy savings for industrial dust extraction systems.
Can an energy-efficient dust extraction system still meet the Control of Substances Hazardous to Health (COSHH) Regulations and Local Exhaust Ventilation (LEV) requirements?
Yes. An energy-efficient extraction system should still provide effective control of airborne dust while meeting the relevant Control of Substances Hazardous to Health (COSHH) Regulations and Local Exhaust Ventilation (LEV) requirements. Energy efficiency should be achieved through appropriate system design and control rather than by reducing the level of protection provided to workers.
Can an existing dust extraction system be upgraded to improve energy efficiency?
In many cases, existing dust extraction systems can be reviewed and upgraded to improve efficiency. Depending on the system, options may include variable speed control, automatic blast gates and demand-controlled extraction technology. A review of the existing system can help determine the most suitable approach.
Can efficient dust extraction reduce maintenance costs?
Potentially. Running extraction fans and other components only when required can reduce unnecessary operating time and wear. Demand-controlled extraction can also help reduce the workload placed on filters and mechanical components, which may contribute to lower maintenance requirements and longer equipment life.
Is demand-controlled dust extraction suitable for woodworking factories?
Yes. Demand-controlled extraction can be particularly effective in woodworking environments where multiple machines operate at different times. The system can direct extraction to machines that are being used rather than continuously extracting from every machine across the factory.
How quickly can an energy-efficient dust extraction system pay for itself?
The return on investment depends on factors including fan size, operating hours, electricity costs, production levels and the existing extraction system. Businesses with high extraction energy consumption may see significant savings, making an energy-efficient system capable of delivering a relatively short payback period.