Principal Doorsets Case Study

A Modernised Dust Extraction Plant

Reducing Waste, Increasing Capacity and Efficiency.

Principal Doorsets based in Barnstaple, Devon . The UK’s Premier Doorset Manufacturer.

Principal Doorsets Ltd are extremely proud of their position as the UK’s Premier Doorset Manufacturer and have accumulated in excess of 550 years in the interior performance timber doorset supply.

Their expertise and broad understanding of joinery and cabinet making industries allows them to offer beautifully finished, high performance interior products in most finishes and designs meeting the most demanding specification and finish requirements.

Their latest CNC machinery gives guaranteed precision and flexibility.

Principal Doorsets seek to deliver outstanding service and quality to their clients and have supplied extensively to prestigious buildings in Healthcare, Education, Leisure, Commercial Building, Hotels and “high end” Residential properties.

A rapidly growing business with innovation and continual improvement at the heart of what they do, Principal Doorsets invest in their partnerships for mutual benefit, with honesty and integrity whether that is their customers, workforce or supply chain.

Principal Doorsets are committed to continue the heritage of door manufacturing within Devon.

When Principal Doorsets Ltd expanded and moved to new premises in Barnstaple, they selected Air Plants Dust Extraction Limited to design, supply and install the dust extraction system serving a Talbott’s Biomass Energy Systems MWE300 boiler plant

Principal Doorsets Site

At the new Barnstaple site, state of the art woodworking machinery is employed in cutting, processing and finishing large quantities of timber based panels which in turn generates high levels of wood waste.

Solution Required

A Baghouse dust collector system to serve their relocated and additional machines including a Talbott’s Biomass Energy Systems MWE300 boiler plant whilst keeping the overall costs to within Principal Doorsets budgeted allowance.

Solution Provided: Air Plants Modulair Filters with Fans, Ductwork and Transfer System

The outset we knew Airplants as we had used them for a previous network installation at our Bideford site in 2014. We went out to completive tender on this latest project looking both separately and system based. There were not many that offer the joined up solutions that Airplants/Talbott’s do. So the selection process was not difficult as there were only three suppliers that were of the quality we sought.

The communication and offer front end was exceptional. Both Air Plant’s Lance and Talbott’s Matt worked on the optimal solution and convinced us that we ought to future proof the installation with the appropriate boiler. We took on board their recommendations of boiler and extraction configuration and placed our order.

The product was on time to the promise I had, lead time was short as we wanted to get ready before moving in plant and equipment that would have hindered access had it been in place. The extraction filter boxes where fully overhauled and new filter sleeves fitted. We had a new fan and motor with a frequency controller fitted to optimise the running of the unit. The electronics were overhauled and linking of the two fan sets with stop, start and emergency stop circuits. The system runs really well and does precisely what was specified.

We now have a system that captures all of our process waste, whether that is directly extracted off the process or via a chipper that is connected into the woodwaste extraction system. There are signals to show when we are making too much that prompts us to slow the chipping of waste.

We have been running the boiler system now 24/7 mainly to manage our waste stream. This has been tremendously helpful to our processes and we have benefitted from quality improvement and process waste reduction, oh and the workforce are comfortable too. We have hot air heat in the factory when required, hot water and hot water piped to our radiators keeping us all comfortable.

We needed help when we first started using the boiler. Talbott’s were very helpful and went out of their way to ensure that we understood what was necessary to run the plant and maintain it at peak condition. We networks Talbott’s technical team in so that on line monitoring and adjustment (Kevin Gibson) could be done. Talbott’s even sent an engineer in to demonstrate how to clean and maintain the system, outstanding!

Stan Bond, 17.05.18

Director, Pricipal Doorsets Ltd

  • Two refurbished Baghouse Dust Collectors; Air Plants Modulair Filters, along with new fans, ductwork and transfer system to the storage bunker of the Talbott’s boiler system.
  • The installed system has a total airflow capacity of 57,000m3/hr, 50% greater capacity than the original system’s 37,000 m3/hr. The two new fans extract 37,000 m3/hr and 20,000m3/hr each.
  • The filtered air is returned to the factory to provide clean replacement air for that being extracted. It also helps the boiler plant run more efficiently.
  • Solid wood waste created during cutting processes is dealt with by an Untha LR630 shredder, reducing the waste to a chip suitable for the boiler plant to handle.
  • The waste is then transferred to the boiler via the extraction plant.
  • The control system links a number of control panels together, with sequencing of the system start up and shutdown processed through a PLC.
Principal Doorsets Installation
Talbott's Biomass Boiler MWE300
Untha LR630 Wood Shredder