In the competitive world of MDF architectural mouldings, staying at the top of the league requires more than just high-speed machinery; it requires an environment that is clean, compliant, and operationally efficient. For SAM Mouldings, a leading UK manufacturer, that environment has been engineered for over 30 years by Dustraction Limited.
The partnership between these two industry stalwarts, founded in 1955 and 1990 respectively, is a masterclass in how a longterm, “no-nonsense” partnership can fuel sustainable growth.
A Legacy of Growth (1995-2011)
The relationship began in 1995, with Dustraction providing a chain filter system for SAM’s site in Antrim. As SAM Mouldings expanded into Europe as a leading manufacturer of interior and exterior MDF mouldings, their waste extraction requirements grew exponentially.
- 1997: Initial installations under the guidance of Sam McCrea and Mark Kirkpatrick.
- 2000–2005: A series of major upgrades to meet increased capacity, including the installation of multiple high-efficiency Cyclo filters, the DX6 and DX9. •
- 2011: A milestone environmental project. Dustraction’s extraction layout supported a Biomass Boiler and steam turbine installation. This system utilised the 2.5 tons of MDF waste generated per hour to create electricity and heat, completely eliminating an annual energy bill of £230,000 and saving 1,200 tonnes of CO2 per year. To support this, Dustraction installed four 80m3 storage silos integrated with two-way diverter valves to ensure a reliable feed source for the CHP (Combined Heat and Power) plant.
The Donington Expansion (2021-2024)
When SAM Mouldings expanded their footprint into England with the Donington site, they faced a significant challenge: managing a waste stream of 6-8 m3 of bulk dust and shavings every hour. To effectively transport this volume of particulate matter away from the production line, Dustraction engineered a high-velocity solution:
- Total air volume: The system moves nearly 76,000 m3/hr of air to ensure all machines remain clear of debris.
- Future-proofing: Recognising SAM’s trajectory, the system was specified with an additional 45% spare capacity, allowing for the seamless addition of further moulding and sawing lines without a complete system overhaul.
- The infrastructure: The heart of the site is a Dustrax 4X9 Cyclo filter, serving a suite of Weinig moulders, beam saws, CNC routers, and double-end tenoners.
2024: Innovations
The latest chapter in this partnership involves SAM’s move toward automated painting.
Dustraction recently installed a DX9 Cyclo filter alongside a specialised Cartridge filter system for a new automated paint line featuring Stemma technology.
To maintain peak efficiency and 24/7 operation, the equipment profile includes:
- Reverse jet cleaning: The Cyclo and Cartridge units utilise a continuous reverse jet cleaning cycle. Short bursts of compressed air are triggered by an electronic controller to dislodge dust cake from the filter sleeves without interrupting operation.
- Bespoke ductwork: A complete external network of highdurability ducting designed to handle the abrasive nature of MDF hogger waste.
Why it works – the “A-Player” standard
For companies the size of SAM Mouldings, extraction isn’t just a “pipe in the wall.” It is a critical piece of infrastructure. Dustraction’s Managing Director, Stephen Duncombe, emphasises that the goal is to provide a “complete design and manufacturing capability from concept to installation.”
“We close our eyes at night knowing that we are saving about 1,200 tonnes of carbon dioxide being pumped into the atmosphere each year,” says Mark Kirkpatrick, Technical Director, SAM Mouldings. “Dustraction was the only company that could handle the high volumes of dust which we create on a daily basis.”
The Dustraction advantage for joinery manufacturers
- Bespoke engineering: Every system is designed in-house using AutoCAD to fit the specific machine layout.
- Biomass integration: Expert layout design to support biomass boiler installations, turning wood waste into a valuable fuel source to eliminate energy bills.
- Proven longevity: Dustraction provides spares and servicing for most makes of filters, even those over 50 years old.
- Compliance & support: Full P601 accredited COSHH LEV Thorough Examination and Testing (TExT), ensuring your facility meets HSE regulations year after year.
