Hallmark Group is New Zealand’s largest NZ-owned door manufacturer, with over 30 years serving the architecture, design, and construction industries. When they developed a new purpose-built manufacturing facility at Rangiora Business Park – set to become one of their key manufacturing hubs – they called on Egmont Air to relocate their extraction equipment and design & install upgraded dust extraction systems for the new site.

Hallmark had existing extraction equipment operating at their previous factory that needed to be relocated and integrated into the new facility. This included an MEC 15, Egmont Air’s industrial dust extractor unit designed for heavy-duty manufacturing environments. The MEC 15 is built for longevity and adaptation – it can be decommissioned, relocated, and recommissioned into upgraded systems when businesses move or expand – making it ideal for a project like this.

The new site required two separate dust extraction systems – one dedicated to treated timber and one to untreated timber – with a combined air volume of 74,000m³/h. Along with the relocated equipment, the project included all new ductwork, upgraded fans, and an expanded filter system. To minimise production downtime, the new systems needed to be installed and commissioned before Hallmark made the move.

The scale of the new facility presented some engineering challenges. With duct runs stretching up to 100 metres, high pressure fans were required to maintain adequate suction across the full length of the system. Fire separation requirements also meant ducting couldn’t pass directly through the firewall – instead, we routed the 900mm diameter ductwork up through the roof and over the wall to connect to the baghouse.

Both systems were installed and commissioned ahead of Hallmark’s move into the new facility, allowing them to transition with minimal disruption to production. The separated systems for treated and untreated timber ensure proper dust management across their manufacturing processes, supporting both air quality and compliance requirements.

Can dust extraction equipment be moved to a new factory?

Yes. Industrial dust extraction units like the MEC 15 are designed for longevity and can be decommissioned, relocated, and recommissioned into new or upgraded systems when businesses move or expand their operations.

Why separate treated and untreated timber dust extraction?

Treated timber contains chemical preservatives that require separate handling and disposal. Running two independent systems ensures proper dust management and compliance with health and safety requirements.

What is a baghouse in dust extraction?

A baghouse is a filtration system that captures fine dust particles from the air using fabric filter bags. Air is drawn through the bags, trapping dust while clean air is released. Baghouses are commonly used in timber, manufacturing, and industrial settings.

How do you maintain suction over long duct runs?

Long duct runs require high pressure fans to maintain adequate suction across the full length of the system. Proper duct sizing and system design are also critical to ensure consistent airflow.

Whether you’re fitting out a new factory or upgrading an existing system, we design and install dust extraction solutions for operations of all sizes. We can work with your architects to ensure your system integrates with your building. Get in touch to discuss your project.