Stylecraft Stairways is one of New Zealand’s leading manufacturers of premium residential staircases, producing everything from carpet-quality stairs to bespoke architectural features incorporating steel, timber, and glass. With the demands of modern manufacturing, factory dust extraction has become essential — not only for air quality and safety but for protecting machinery and keeping production running efficiently. That’s why for the past 10 years, Egmont Air has worked with Stylecraft to support them with tailored, future-proofed extraction solutions at each stage of their business expansion.
“Health and safety is an ever-increasing concern. Getting on top of our dust is really key. Engaging with a reputable company to fulfill our dust extraction needs has greatly helped us overcome this problem.”
— Martin Turley, Stylecraft Stairways
Over this time, Egmont Air has partnered with Stylecraft to improve air quality, minimise downtime, and support major factory upgrades—all through smart, reliable factory dust extraction systems.
2015: Recovering After a Fire With a New 3-Module Factory Dust Extraction System
After a fire in 2015, Stylecraft needed to rebuild quickly but also improve their workshop environment. Egmont Air installed a 3‑module dust extraction system, laying the foundation for a cleaner, safer, and more efficient production space.
2019: Factory Upgrade & the Addition of a Second Dust Extractor
As Stylecraft expanded their capabilities—including additional CNC machinery—they required greater extraction capacity. Egmont Air installed a second dust extractor running in parallel with the original unit, bringing:
- Flexibility during busy production periods
- More efficient factory dust extraction across multiple zones
- Increased output without compromising air quality
2023: Designing a New Factory & Relocating Extraction Without Downtime
When plans were made to build a new factory alongside the existing one, the challenge was clear: the dust extractors were sitting exactly where the new structure needed to go.
Egmont Air worked with Stylecraft to develop a detailed masterplan to relocate the dust extraction systems—while keeping the workshop fully operational throughout construction.
This staging allowed construction to continue smoothly with zero production downtime.
2024: A Purpose-Built Facility with Smarter, Cleaner, More Efficient Factory Dust Extraction
Once the new facility was completed, Egmont Air installed a refined, future-focused extraction layout.
Two Main Ducts, Cleanly Aligned
One of Stylecraft’s main concerns was ensuring ductwork didn’t block lighting or cast shadows on work areas. Egmont Air routed the two main ducts above each other, keeping the factory bright and improving overall workflow.
“One of the key concerns was that the ducting route didn’t interfere with good lighting. Egmont Air ran both ducting systems on top of each other to minimise any shadows.”
— Martin Turley
Variable Fan Speed for Energy Efficiency
Smart motor control ensures the factory dust extraction fans only use full power when needed—cutting electricity costs and reducing overall wear.
Combined Discharge for Continuous Operation
Both extractors now feed into a single bin-load circuit, filling a 20’ container that’s emptied monthly with no machine shutdowns.
Previously, operators stopped each system 15–20 minutes every day to swap bins—now eliminated thanks to the improved factory dust extraction system.
Why Factory Dust Extraction Matters for CNC Performance & Product Quality
Stylecraft run three CNC machines that require an ultra-clean environment.
“If you get dust into the bearings, that could be $14,000 to $20,000. If you just had a good dust extractor, that eliminates the risks and costs of repairs and downtime”
— Martin Turley
Effective factory dust extraction protects machines, improves efficiency, and ensures customers receive higher-quality products faster.
A Long-Term Partnership Built on Smart Planning & Clear Communication
Through continuous collaboration, Egmont Air provided detailed shop drawings, layout planning, and staged installation timelines—ensuring every part of the factory dust extraction system seamlessly integrated with Stylecraft’s evolving production environment.
The Result: Cleaner Air, Higher Productivity, Lower Costs
Thanks to Egmont Air’s extraction solutions, Stylecraft now benefits from:
- Improved air quality
- Reduced machine maintenance costs
- Zero downtime for bin changes
- Better lighting and cleaner workflow
- A future-proof dust extraction setup
“I would highly recommend getting in touch with Egmont Air for any joinery shop wishing to maintain good air quality and a productive environment.”
— Martin Turley
Ready to Improve Your Factory Dust Extraction?
Egmont Air specialises in dust and fume extraction systems designed for joinery, CNC workshops, and manufacturing facilities of all sizes.
Contact Egmont Air today to begin planning a cleaner, more efficient workshop environment.