Moving from a site in Harpenden, which they had occupied for 23 years, to a contemporary 11,500ft2 facility in Welwyn Garden City, provided Hydewood with the opportunity to transform their production operation with the implementation of a modern, efficient layout.
Run by husband and wife team, Peter and June Bush, Hydewood produces high quality turned products for clients in the upholstery and furniture manufacturing sectors.
Queen Anne, Georgian, Louie and Spade Toe legs, as well as bun feet, stools, stair spindles and table lamps, are all included in the large portfolio of products manufactured by Hydewood. With a dedicated team of long-standing employees, everyone at Hydewood is justifiably proud of the firm’s reputation for quality and first class service.
Peter Bush says: “Over the years our old premises had become somewhat crowded as new machines were installed and, with the planned move to new premises, we were keen to ensure that we should make the best possible use of the available space. It was also time to replace our existing dust plant and we knew that the dust extraction installation would play a key role in planning the layout of the factory.”
Dust Control Systems was called in at an early planning stage and was involved throughout the relocation process – working closely with Hydewood, DCS was able to recommend an optimum machinery layout and accurately assess dust extraction requirements for the new factory.
Melvyn Bathgate, sales director at DCS, says: “With so many machines to be re-installed and commissioned, the move necessitated a two-week production shutdown, but our engineers were able to install the complete extraction plant in advance of the closure, and pre-install extraction points ready for machinery to be moved into place.”
The new extraction system was sized on a duty of 42,300 m3 per hour, and comprises a high-efficiency, externally located, modular filter unit with two 37kW low-noise main fan sets. Waste collected in the filter is discharged pressure-free via a rotary valve into a closed-loop waste transfer system, which transports the waste to sealed boxcarts.
Energy-saving measures involved the installation of an Ecogate extraction optimisation system which employs two Ecogate greenBOX12 controllers, together with variable speed drives to both main fans.
The greenBOX12 detects changes in extraction load and adjusts the variable speed fan drive accordingly. The result is a highly-efficient dust extraction system, providing precise extraction volumes, only when needed, and reduced noise levels in the production facility. Ecogate confidently expects that the system will reduce power usage by around 60% when compared with a traditional fixed-speed system.
Melvyn Bathgate adds: “For the Hydewood project we were able to call upon other expertise within the DCS Group by supplying and installing two Gallito bench-type spray booths and exhaust stacks, as well as specifying a manually-fed workshop heater which is fuelled by wood offcuts.”
Obviously delighted with their new premises, Peter and June Bush are quick to acknowledge the contribution made by DCS: “The project was handled in a very professional and caring way,” says Peter Bush, “and we have nothing but admiration for the input and expertise of the DCS team in helping us kick-start a new era for Hydewood.”