Premier Forest Products embraces Ecogate® efficiency with Extractly
- PWT
- Nov 3
- 4 min read
Headquartered at Alexandra Docks, Newport, South Wales, Premier Forest Products has, over the last three decades, evolved into one of the UK’s leading independent timber companies
Operating multiple sites across the UK, with over 450 employees, Premier Forest specialises in the importation, distribution, machining, engineering and processing of timber and timber products.
The company’s extensive product range covers almost every conceivable timber item. However, as with any business delivering more than 400 tonnes of timber goods on a daily basis, a significant volume of dust waste is inevitably produced through its various manufacturing processes.
This impressive growth has been fuelled by a combination of strategic acquisitions and ongoing investment in high-speed production machinery. Integrating new machinery into the production area inevitably places fresh demands on the extraction systems. In 2023, Ian Rayner, UK Sales Manager for dust extraction specialist Extractly Ltd, was invited to assess requirements for upgrading the extraction system at Premier Forest’s three-acre manufacturing site in Haverfordwest, Pembrokeshire – formerly Merlwood Timber.
In addition to supplying a wide range of sawn timber products to landscapers and builders, Premier Forest’s substantial machinery investments have expanded capacity to include the production of hardwood and softwood mouldings and claddings.
Significant efficiency gains
Extractly Ltd, the master UK distributor and installer of the globally proven Ecogate® ‘on-demand’ extraction technology, identified an opportunity for Premier Forest to benefit from significant efficiency gains.“With the addition of new machinery and increased production, dust and wood waste extraction capacity was being pushed to its limits at the Haverfordwest site,” explains Ian Rayner.
Although the existing filter unit had reached capacity, it remained serviceable. Extractly’s brief was to design and install a new ductwork system throughout the factory to efficiently service the upgraded and reorganised production lines, while also providing an option to incorporate Ecogate® technology.
“With an Ecogate® extraction-on-demand system, instead of running at full speed all day, every day, fan speed is automatically reduced whenever machines are idle,” says Ian. “In most woodworking factories, fan usage can typically be reduced by at least 20%.”
Due to the laws of physics, a 20% reduction in fan speed equates to a 50% reduction in electricity usage. With Ecogate® controlling a powerful 55kW main fan at Haverfordwest, the resulting energy savings quickly become substantial. Reduced operating hours also mean lower maintenance requirements and extended fan life.The Ecogate® system is programmable to start extraction automatically at the beginning of the day, run filter cleaning cycles at optimal times, and shut down safely at day’s end. Improved efficiency, reduced fan speeds and better cleaning cycles extend the life of the filter media. Another noticeable benefit has been lower noise levels throughout the factory.
The filter unit is currently housed in a separate building below the main production area – a factor that originally required a high-powered fan. When the filter unit is eventually replaced, relocating it closer to the factory floor will allow for a smaller, more cost-effective fan and an even quieter working environment.
To ensure that all Premier Forest LEV systems remain compliant with HSE HSG258 guidelines and COSHH regulations, Extractly Ltd has also been commissioned to review and service extraction systems across the company’s multiple manufacturing sites. Extractly’s experienced engineers now conduct scheduled LEV testing and routine maintenance.
Other new systems
At Premier Forest’s Duchy Timber branch in Cornwall, Extractly supplied and installed a new extraction system featuring a 10,500m³/hr ATEX filter unit – first seen at the 2024 Materials & Finishes Show – alongside an 18.5kW main fan, full ductwork and an ATEX non-return explosion valve.
Most recently, Extractly completed a comprehensive new extraction system for Decorpanel, Premier Forest’s panel-processing division at Newport. This branch offers extensive processing services – from cutting, drilling, routing and edging, to laminating, veneering, painting and lacquering.
The Newport system features a 75kW externally mounted ‘clean side’ fan, capable of drawing up to 40,000m³/hr of air into an ATEX 4+1 chain filter unit. Waste material is discharged via a rotary valve and a 15kW fan transports the collected dust and shavings to a dual-trailer storage system with automated diverters.
Internally, Extractly installed Nordfab Quick-Fit ducting, a non-return explosion valve and additional safety features, including a spark detection system and a steel bullet magnet.
As with the Haverfordwest site and other Decorpanel operations in North East England, Ecogate® on-demand technology was again installed to manage the system. Each machine sends a signal to a greenBOX Nxt controller, which in turn instructs the Ecogate® PowerMaster Variable Speed Drive to adjust fan speed in real time to match extraction demand.
“At Premier Forest Products, we take site safety very seriously,” affirms Gareth Howells, Health & Safety Manager. “From my experience with Extractly’s design and installation teams, I’m confident that our dust extraction systems are of the highest standard, delivering safe, clean environments for our employees.”
For further information on Extractly Limited, see contact details below:
T: 01924 520 462
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