Project highlights from the past year: Taking our dust and fume extraction solutions across the UK
Matt Brown | Published December 19th 2025 | Updated December 19th 2025
As 2025 draws to a close, we are taking a moment to reflect on some of the projects that have defined our year, as we’ve partnered with businesses across the UK to deliver efficient dust extraction solutions. From tea processing to biscuit manufacturing, our dust extraction systems have supported a wide range of operations, helping customers keep their staff safe and their production lines running smoothly.
Replacing a legacy dust extraction system with a state-of-the-art dust collector at Fox’s Biscuits
Our brief from Fox’s Biscuits was simple: design and install a dust extraction system that covered all of its Batley site’s dust release processes, while offering prolonged performance levels.
The firm came to us with the problem of a legacy dust extraction system which, alongside not covering all areas of the factory, had also seen drop offs in performance year on year, meaning airborne dust was being released.
Our main challenge was working and designing the system around factory processes that had high levels of operator movement and interference, and hadn’t been built to accommodate dust control. We also had a short window of time to complete the eventual install, taking place during the Easter Bank Holiday.
To combat the operator interference challenge, we designed a dust extraction solution with moveable hoods, allowing for flexibility on the factory floor. Our solution involved a highly specified reverse jet cartridge dust collector complete with full ATEX ancillary items, and we created a significant ducting network spreading to all areas of the factory requiring dust control.
We took Fox’s from three underperforming systems down to one, state-of-the-art extraction system, condensing their maintenance regime while giving the operational team peace of mind that all dust release zones are being controlled.
A big part of the solution was the close collaboration between ourselves and the Fox’s team – something our Area Sales Manager, Alex emphasised, saying “we worked directly with the Fox’s team to build a bespoke solution, which helps, not hinders, their current operations.”
This sentiment was echoed by the Fox’s team, who said “the attention to detail, ability to work to tight deadlines and the professionalism from all APS employees” made it “an extremely satisfying project to bring to life.”
Helping Finlay Beverages increase its safety and operational efficiency
Have you ever thought about the processes involved in making tea, before it reaches your mug? We have! Earlier this year, we worked with the UK’s leading own brand tea and coffee partner, Finlay Beverages to collect fine tea dust generated during the fluid bed drying process, which dries tea leaves ready for further processing.
Our task was to replace an old wet scrubber system, which was expensive to operate, using a high KW fan and huge amounts of water. Finlay Beverages needed a more cost-effective system, which could help them increase the efficiency of their operations.
With dust extraction critical to Finlay Beverages’ processes, we only had a short period of time to install the new system to ensure the operations team could continue making decaffeinated tea. We had to extensively plan before the install took place, working around the constraints that come with a tight space.
We installed a high-efficiency Donaldson DFE reverse jet dust collector with full ATEX protection to safely capture fine tea dust from the fluid bed dryer. The system includes explosion venting, and a hopper with rotary airlock discharging into an FIBC. Clean air is discharged externally via a floor-mounted fan and extended ductwork, all managed through a Siemens PLC and HMI control system with temperature monitoring to protect the equipment.
The new solution significantly reduces operating costs compared to the previous wet scrubber, improves process efficiency, and supports compliance with health and safety regulations, while enhancing overall site safety through its ATEX-certified design.
Keeping production up and running at Bright Steels
We don’t just work with food and beverage companies – we work across the entirety of the manufacturing sector, from pharmaceuticals, to plastics, and even to metals.
Steel specialist Bright Steels came to us with the problem of an existing dust extraction system which was regularly failing, meaning heavy metal dust from production wasn’t being properly captured.
Bright Steels needed a high-performance, low-maintenance solution that could be installed quickly, without halting their operations for an extended period. Adding to the challenge, we had to work within the constraints of a low-roofed factory space with complex steelwork.
We installed a Donaldson DFE reverse jet cartridge filter unit with an abrasive-resistant inlet, twin hopper section fitted with Mancuna discharge valves, and sprinkler heads. The reverse pulse jet system automatically cleans the filter cartridges, maintaining consistent airflow and filtration efficiency. The system also includes fully automatic filter cleaning, a floor-mounted high-efficiency fan, secondary HEPA filter housing, and an emission monitoring system to ensure compliance with COSHH regulations. Heavy-duty welded and painted ductwork connected the collector to the shotblast machine, while an automatic pre-coat dosing system protects the filter media.
The new system effectively captures heavy metal dust at source, keeping staff safe and ensuring regulatory compliance. Bright Steels chose APS because of our expertise, technical knowledge, and strong partnership with Donaldson, with Head Engineer Simon Stannard saying “I’ve found that everyone involved in the project at APS has been professional and totally competent in their work, and the dust collection unit is running well. This has been such a refreshing change from some of the projects that I’ve been involved with, and I’m pleased it’s all gone so smoothly.”
Want to be the face of our next great dust extraction project?
If you’re ready to introduce a new state of the art dust collector to your production line, get in touch with our friendly, expert team today, and we’ll design, install, and maintain a bespoke dust extraction solution that suits your needs.
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