In the competitive world of custom kitchen and cabinetry manufacturing, operational efficiency and workplace safety go hand in hand. For Russell Reardon, Managing Director of Kitchens R Us at Mt Maunganui, the decision to upgrade to advanced dust extraction has proven to be a game-changing investment that revolutionised both productivity and working conditions. This family-owned, family-run business has been operating from their Mount Maunganui factory since 1987, building a reputation as one of New Zealand’s most trusted brands in kitchen manufacturing through their commitment to quality craftsmanship and community involvement.
The Challenge: Outgrowing the Old System
Kitchens R Us, a comprehensive one-stop shop specialising in kitchens, wardrobes, and storage solutions, found themselves at a crossroads. Their existing dust extraction system was struggling to keep pace with their growing operations and expanding machinery lineup, including new CNC machines and beam saws. The old cyclone system simply couldn’t provide adequate suction across multiple machines operating simultaneously, creating bottlenecks in production and compromising air quality in the workshop.
“With our old system, we were limited in how many machines we could run at once,” explains Reardon. “It was holding back our production capacity and creating a dusty, noisy work environment that wasn’t ideal for our team.” For a business with nearly four decades of experience and AMOTAI registration, maintaining high standards was crucial.
The Egmont Air Solution
When Kitchens R Us reached out to Egmont Air for a comprehensive solution, the team knew this project required careful analysis and custom engineering. Richard Stewart from Egmont Air conducted a thorough site evaluation, calculating the total airflow with all machines operating simultaneously.
The challenge was significant: design an advanced dust extraction system that could handle the substantial airflow demands while providing flexibility for future expansion. Egmont Air’s response was the Modular 40Hp Dust Extraction Upgrade System, featuring their renowned modular bag-house design that replaced the aging cyclone system.
The new advanced dust extraction system showcases several key innovations that set Egmont Air’s technology apart from conventional solutions:
High-Efficiency Fan Technology: The system features Egmont Air’s proprietary reverse incline impeller design, delivering superior airflow-pressure compared to traditional paddle-blade fans. The direct-drive configuration eliminates belt-drive losses, maximising efficiency while reducing energy consumption.
Modular Construction: Understanding that manufacturing businesses evolve, the system’s modular design allows for future upgrades and modifications without requiring complete replacement. This future-proofing approach ensures the investment continues to deliver value as operations expand.
Advanced Filtration: The generous filter surface area and high-efficiency filter media capture even the finest particles, ensuring clean air discharge that exceeds stringent environmental regulations. The automatic filter cleaning system maintains optimal performance without manual intervention.
Smart Power Management: Perhaps most impressive is the integrated Variable Speed Drive (VSD) system with pressure transducer technology. This intelligent system automatically adjusts fan speed based on real-time suction demands, delivering substantial energy savings while maintaining optimal performance.
Outstanding Results: Production Capacity Doubled
The results at Kitchens R Us have been nothing short of remarkable. “Outstanding, no comparison, massive difference” are Russell Reardon’s words when describing the advanced dust extraction system’s performance. The results speak for themselves:
Production Capacity: “With the new system, the reality is we can double the amount of machines operating at the same time, and it actually gives us the ability to run everything” notes Reardon. This dramatic increase in operational flexibility has allowed the company to take on larger projects and reduce lead times.
Air Quality Improvement: “It’s really dropped the level of dust in the factory significantly, the factory’s a lot cleaner” Reardon observes. This improvement in air quality isn’t just about aesthetics – it’s about creating a healthier work environment and reducing long-term health risks for employees.
Workplace Environment: The noise reduction and cleaner air have had a profound impact on staff satisfaction. “It is quieter, the team are much happier, it’s a way better working environment” Reardon confirms. Happy employees are more productive employees, creating a positive feedback loop that benefits the entire operation.
Energy Efficiency: The VSD system’s power-saving capabilities can deliver substantial ongoing savings. In similar advanced dust extraction installations, clients have reported annual energy savings of up to $6,000, based on a 50% power reduction through intelligent fan speed management.
Looking Forward: Built for Growth
The modular nature of Egmont Air’s advanced dust extraction systems means that as Kitchens R Us continues to grow and evolve, their system can adapt accordingly. Whether adding new machinery, expanding floor space, or upgrading to more advanced equipment, the foundation is already in place to support future ambitions.
For manufacturing businesses facing similar challenges with outdated systems, the Kitchens R Us success story demonstrates the potential of investing in advanced dust extraction technology. The combination of improved productivity, enhanced workplace safety, reduced energy costs, and future flexibility creates a compelling business case that extends far beyond the initial investment.
Russell Reardon’s enthusiasm is infectious: “The suction is incredible, it’s miles better, there’s no comparison to the old unit.” For Egmont Air, this kind of customer satisfaction represents the ultimate measure of success – technology that doesn’t just meet specifications, but changes how businesses operate.
Ready to upgrade your dust extraction system? Don’t let outdated equipment hold back your production capacity or compromise your workplace environment. Contact Egmont Air today to discuss how advanced dust extraction can benefit your operation. Our team of experts will evaluate your specific requirements and design a solution that delivers measurable results.