When Floorscape, a premier flooring solutions company, needed to upgrade their dust extraction system capabilities, they approached Egmont Air for a comprehensive solution that would keep their workshop clean, safe, and productive.
The Challenge
Operating a busy flooring workshop presents unique challenges when it comes to maintaining air quality and workplace safety. Floorscape’s facility required effective dust extraction for multiple drop saws operating simultaneously, generating approximately 2,120m³/hr of airflow. The company faced the common issues that plague many manufacturing environments: airborne dust particles affecting worker health, time-consuming cleanup processes, and the risk of dust buildup causing equipment blockages and premature wear on cutting tools.
Beyond these immediate operational concerns, Floorscape also needed to ensure compliance with New Zealand’s Resource Management Act requirements for discharge emissions. The company required a system that could handle the demanding workload of their facility while maintaining clean air discharge standards and creating a healthier working environment for their team.
The Egmont Air Solution
After conducting a thorough on-site assessment with Diego from Floorscape, Egmont Air’s technical team recommended their MFM2 Dust Extraction System – specifically engineered for New Zealand’s medium-sized manufacturing facilities. This system represents years of development focused on addressing the unique challenges faced by Kiwi manufacturers.
Core Components
The heart of the system centres around the MFM2 Filter Unit, which features generous filter surface area designed to provide high filtering efficiency while ensuring compliance with clean air discharge regulations. This is paired with a 5.5HP High-Efficiency Fan that delivers optimal air volume and duty, maintaining powerful suction even across extended ducting runs.
The system includes complete ducting connection to 4 machines, ensuring comprehensive coverage across Floorscape’s workshop operations. The entire setup is built around a galvanised frame and panel construction specifically designed to withstand New Zealand’s outdoor conditions, providing years of reliable service with minimal maintenance requirements.
Smart Technology Investment
After evaluating their options, Floorscape made the strategic decision to invest in the Variable Speed Drive (VSD) and Fan-Starter upgrade. This intelligent control system combines five essential devices into one sophisticated unit:
- Complete fan starter functionality for reliable operation
- Sensitive motor overload protection to prevent equipment damage
- Adjustable ramp speed control allowing for customisable suction levels
- Significant power savings through intelligent airflow management
- Advanced motor controls with user-friendly LED screen interface
This upgrade transforms a basic extraction system into an intelligent, responsive solution that adapts to varying operational demands throughout the day.
Measurable Results and Benefits
The VSD upgrade delivers impressive efficiency gains that make a real difference to Floorscape’s bottom line. The system is able to generate approximately $800 in annual power savings through intelligent speed control, demonstrating how smart technology can deliver ongoing operational benefits.
The engineering behind this efficiency is remarkable: a modest 20% decrease in airflow when optimised results in a substantial 50% power reduction. This means Floorscape can
maintain excellent dust extraction performance while dramatically reducing their energy consumption. The system also ensures full compliance with Resource Management Act requirements for discharge emissions, giving the company peace of mind regarding their environmental responsibilities.
Workshop Improvements
The transformation in Floorscape’s workshop environment has been significant across multiple areas. The high-efficiency filter media effectively captures fine sanding dust and particleboard particles, creating noticeably cleaner air quality throughout the facility. This translates directly into increased productivity, as workers spend considerably less time on end-of-day cleanuproutines.
From an equipment maintenance perspective, the system prevents dust buildup that previously caused blockages and contributed to excessive wear on cutting tools. This protection extends equipment life and reduces unexpected downtime, contributing to easier and more efficient daily operations.
Most importantly, the dramatically reduced airborne particles create a healthier working environment for Floorscape’s team, supporting both team wellbeing and regulatory compliance.
Diego Bombardiere Moreno, Technical Manager at Floorscape, shares his perspective on the transformation:
“The new system has made a huge difference, beforehand there was dust everywhere. The fine dusts used to go all through the factory, but now it’s gone and the area is much cleaner. The difference is amazing, we’d recommend Egmont Air any day. It’s just so good to have a proper system installed.”
Why Floorscape Chose Egmont Air
The decision came down to a combination of proven performance and dedicated local expertise. Egmont Air offers European quality standards backed by comprehensive local service and support, ensuring that technical assistance is always available when needed.
The company’s proven track record across New Zealand’s manufacturing sector provided Floorscape with confidence in their investment. Every system comes with a complete guarantee on quality and performance, supported by ongoing technical support from Egmont Air’s experienced team.
The Bottom Line
Floorscape’s investment in the Egmont Air system shows how smart business thinking can deliver on multiple fronts. The system combines immediate workshop improvements with substantial long-term operational savings, essentially paying for itself through energy and efficiency gains while improving the working environment for their team.
For manufacturing facilities considering dust extraction upgrades, Floorscape’s success story shows how the right system can deliver measurable improvements in air quality, energy efficiency, and overall workshop productivity.
Contact Egmont Air today to discuss how our dust extraction solutions can enhance your workshop environment.