Dunkelman & Son Ltd has transformed its Northamptonshire production facility with a new dust extraction system by Dutch family business Modesta in partnership with UK-based Extraction Solutions Ltd. Together, they delivered a bespoke, energy-efficient system that ensures cleaner, safer working conditions for Dunkelman’s staff while supporting their long tradition of crafting premium wooden shoe trees.
Starting out as a family business in a small London workshop in 1946 and then moving to central England in the sixties, Dunkelman & Son Ltd has built a strong reputation in the past 80 years for manufacturing and distributing highquality shoe and leather care products and accessories.
In 2018, the company opened a new production facility on a 3.3-acre site in Desborough, Northamptonshire, reviving their legacy of local shoe tree manufacturing in the heart of the UK’s shoemaking region. Now owned by French family company Alma F.R.C., Dunkelman continues to keep the British craft alive. “We’re proud to say we produce our shoe trees completely in-house, from start to finish,” says Steve Keenan, warehouse manager at Dunkelman & Son.
A custom-engineered solution
Two years ago, Dunkelman sought a partner to help them equip their new production facility with a robust dust extraction system. “Guaranteeing a healthy and safe working environment for our staff is of utmost importance,” explains Steve. “In our previous set-up, we had a dust problem, so we needed an easy-to-use, efficient solution that would eliminate downtime and improve waste disposal.”
After evaluating several options, Dunkelman selected Extraction Solutions Limited, a Sheffield-based family business specialising in wood waste handling and dust extraction. “Our initial site assessment allowed us to enhance the original design by selecting a more efficient filter location,” says James Parkes of Extraction Solutions Ltd. “This not only improved the current waste collection method but also enabled us to carry out the installation alongside the existing equipment, eliminating the need for costly downtime.”
Steve recalls the communication with Extraction Solutions as pleasant and efficient from the very start. “They handled everything, from the initial concept and design, through installation and commissioning, to the final handover.” Extraction Solutions recommended a fully tailored system by Dutch manufacturer Modesta, using a CF80 chain filter and several negative-pressure clean air fans, providing a total dust extraction capacity of 45,000 m³/h.
"This solution stood out to us because of its user-friendliness and energy efficiency,” says Steve. “Modesta’s filters contain several fans, which allows us to use only the required capacity and reduce energy consumption.”
ESL didn’t just recommend any supplier: they have a long-standing relationship with Modesta. Now led by the third generation of the Kloppenburg family, the Dutch company has more than 75 years of experience in dust extraction. They offer modular installations with high efficiency and low operational costs. Building all their systems in-house in the Netherlands, they have an international client base in the wood, agriculture, and recycling sectors.
“The UK has always been an important market for us: that’s why we’ve partnered with ESL, so we have a local partner to help us out with the distribution and installation of our UK-based projects,” explains Wyboud Kloppenburg, Modesta’s managing director. “This project marks an important milestone in our partnership: it’s the first time ESL has handled the project entirely independently, from design to installation, while we supplied the filtration technology. It’s a great example of collaboration between our two family businesses.”
Cleaner factory, happier staff
The new system has now been in operation for several months, and the results speak for themselves. “Our production has been cleaner since we started using the system. It’s a more pleasant environment for all our staff,” says Steve. “Our machinery needs less downtime for cleaning, which means higher daily output.”
Ease of use was another win: “We literally just turn it on in the morning and off at the end of the shift. When the dust bins are full, the display tells us – it couldn’t be simpler,” Steve explains. With Extraction Solutions’ expertise and Modesta’s proven technology, Dunkelman has achieved a cleaner, safer, and more efficient manufacturing environment – one that supports their proud British heritage while looking firmly to the future.
