Cresswood Shredding Machinery, an Illinois-based company, has been innovating in manufacturing for over 40 years. Their journey began in 1979, crafting residential stoves and fireplace inserts. Over time, they evolved into the realm of industrial furnaces, and then automated boiler systems.
Initially, they utilized German grinders for wood, paper, and plastic to grind material for boiler stokers. After a while, they were not satisfied with the quality of the imported product. So, Cresswood decided to design and build their own grinders – a venture they have successfully undertaken for the past 35 years.
This pivotal shift, however, presented a new challenge: dust and smoke. That is because a crucial aspect of their shredder manufacturing process involved using flex core welding wire, which generated a significant amount of smoke. As Jack Cress, CEO of Cresswood Shredding Machinery, explains, “One of the critical aspects of a weld shop is smoke.”
Cresswood had tried various solutions to combat the welding smoke. They experimented with fume extraction systems attached directly to the welding guns and employed fans to try to pull the smoke out of the building entirely. Unfortunately, none of these methods proved truly effective.
A Breath of Fresh Air: The Imperial Systems Solution
Employee retention is a significant concern across many industries, and Cresswood recognized the importance of fostering a pleasant work environment. Jack explains, “For the last 20 years, it’s been a serious problem to create an environment that employees want to work in.” Clean air was certainly a key piece of that puzzle.
Jeremiah Wann at Imperial Systems listened to Jack’s concerns and proposed a solution: the Shadow Compact Fume Extractor. This innovative system proved to be a significant change for Cresswood Shredding Machinery. Shop employees finally had a smoke-free environment to work in.
“It’s very difficult to get employees and employee retention, and part of that is creating an environment where they want to work,” emphasizes Jack. The impact of the Imperial Systems solution goes beyond just improved air quality; it contributes to a happier, healthier workforce.
Cresswood Shredding Machinery’s story exemplifies the power of innovative solutions. By partnering with a company like Imperial Systems, they were able to address a longstanding challenge and create a more positive work environment for their employees. This not only benefits worker well-being but also contributes to a more productive and successful company overall.
For any automotive outfitter, a clean and healthy work environment is paramount. But for this North Carolina-based company, achieving that goal presented a unique challenge – dust. Their fiberglass operation generated significant airborne particles, impacting product quality and employee well-being. Further, as they transitioned into a new building, they knew they needed a robust dust collection system designed for their specific needs.
This North Carolina automotive outfitter was expanding their operation into a new building, and adding processes that required dust collection. However, their existing dust collection system, designed for their previous space, simply wouldn’t suffice. Their high-output machines, including saws and multi-head sanders, produced more dust than the old system could handle
“It simply would have overwhelmed our system and dust would have been everywhere,” a company representative recalls. Not only would this have impacted the quality of their work, but it also posed health and safety concerns for their employees.
Finding the Perfect Fit: Automotive Outfitter Searches for a Tailored Dust Collection Solution
Knowing they needed a tailored solution, the company embarked on a search for a dust collection partner. They prioritized finding a company that could not only deliver a powerful system but also a system that would work with their specific needs. This application needed a source capture system that would collect debris directly at the point of generation.
After careful consideration, they chose to work with Imperial Systems. “We felt that Imperial delivered the most value, as well as gave us the highest level of confidence that they were going to deliver a turnkey solution,” their representative explained.
Imperial Systems rose to the challenge, designing and installing a CMAXX Dust and Fume Collector specifically engineered for the automotive outfitter’s unique needs. The new system boasts a much higher capture rate, effectively preventing dust from spreading throughout the facility.
Imperial Systems: Committed to Excellence
This has yielded significant benefits for both the company and its employees. The increased material removal rate translates to improved efficiency and productivity. More importantly, employees experience great air quality within the shop. The CMAXX has been able to keep the new building clean.
The company is particularly impressed with Imperial Systems’ dedication to service. “We’re definitely impressed with the team,” they say. The system was installed in the middle of July on a roof in North Carolina. The team worked sun up to sun down daily to ensure the unit was installed on time.
At the time of the interview, the 96 filters within the dust collector haven’t required replacement. A representative reports that the differential pressure is still very low, at almost new conditions. “We have not had to change our filters in a year and a half,” they said. This not only saves them money but also minimizes downtime for maintenance.
The new dust collection system from Imperial Systems has been a game-changer for this North Carolina automotive outfitter. They are extracting more dust than ever, resulting in a cleaner, healthier work environment, improved product quality, and increased efficiency. This success story serves as a testament to the power of partnering with a company that understands the specific needs of its clients and delivers exceptional service every step of the way.
Cronimet Specialty Metals, a metals recycling facility, recently faced a unique challenge in its operations. The nature of their work with specialized materials – stainless steel, tungsten, and cobalt – necessitates the use of powdered catalysts. While essential to the process, these catalysts generated airborne dust. Additionally, losing this valuable material represented a missed opportunity for resource recovery.
Balancing Air Quality and Resource Recovery in Recycling
Other dust collection systems, while effective for general particulate control, wouldn’t suffice for Cronimet’s specific recycling needs. They required a solution that not only minimized dust but also facilitated the crucial reclamation of the catalyst material for continued use.
Custom-Designed Solution: Imperial Meets the Challenge
Partnering with Imperial Systems, Cronimet was able to implement a customized dust collection system designed to address their unique challenges. Imperial Systems’ team of experts understood the critical nature of both air quality control and resource recovery. Their solution effectively minimized airborne particulates within the facility while simultaneously enabling the efficient reclamation of the dust for further utilization in the recycling process.
Beyond Clean Air: Recovering Revenue and Setting a New Standard
The positive impact of the implemented system extends beyond air quality benefits. “We’re recovering lost revenue when it was just going into the air, onto the walls, and onto the floors,” said Robert Taylor, who works in maintenance at Cronimet Specialty Metals. “It worked better than our expectations.”
The collaboration between Cronimet Specialty Metals and Imperial Systems goes beyond the technical aspects of the dust collection system. Taylor emphasizes the exceptional level of customer service provided by the Imperial Systems team. “Everyone at Imperial Systems just goes out of their way to answer all the questions and make sure we got everything we wanted, and we did,” said Taylor in a testament to Imperial Systems’ commitment to client satisfaction.
By leveraging Imperial Systems’ expertise in dust collection technology, Cronimet Specialty Metals is not only achieving a more sustainable recycling process but also establishing a new standard for responsible and efficient metal resource recovery. When it’s time to purchase additional dust collectors, Taylor made it clear which manufacturer the company would be going with. “We’ve used other manufacturers. I won’t use their name, but there’s a big one that’s blue. I think the quality, comparing this system to competitors, is so much better,” said Taylor.
Excel Industries, a Kansas-based manufacturer, invented zero-turn mowers and produces Hustler and Big Dog brands. Due to the welding area of their production facility, they needed a fume extraction solution. As a result, Imperial Systems provided dust collection that greatly improved air quality and efficiency at Excel’s facility.
Challenges at Excel Industries
Excel Industries faced two main challenges. With over 50 manual welders, Excel’s top priority was employee health. “First and foremost was the wellbeing of our employees. We really wanted to create a good, healthy, and comfortable environment for our welders,” said Christopher Waldron, senior welding engineer. Because inhaling welding fumes can cause respiratory problems, Excel wanted to ensure their employees could breathe easily throughout the workday.
Maintaining a clean and efficient shop floor was also important. That is because dust and particulate matter can create a messy work environment and potentially affect product quality. Additionally, finding a dust collector that required minimal maintenance and didn’t take up valuable floor space was crucial. “Floor space was a premium for us,” said Waldron.
Additional Considerations
Excel was also seeking a unit that needed minimal maintenance and didn’t need constant attention from staff. Because they experience the variety of weather in Kansas, returning heated or cooled air back into the facility is very important. This feature saves both electricity and money in the long run.
Why Excel Industries Chose Imperial Systems
After considering various options, Excel Industries decided to partner with Imperial Systems for several reasons:
Longevity: Imperial System’s lifetime warranty on the CMAXX Dust & Fume Collector appealed to Excel. “We were really interested in a unit that would last a long time,” said Waldron. The CMAXX’s arched roof and rain guard make it stand the test of time even in outdoor applications.
Safety Pentagon Approach: Imperial Systems’ commitment to safety resonated with Excel. Their dust collectors featured innovative solutions to prevent incorrect operation or filter loading, ensuring the safety of Excel’s employees.
Responsive Sales Team: Excel appreciated the dedicated attention they received from Imperial Systems’ team. “Their sales team was responsive. They were always there to answer our questions. It felt like we got a more personalized experience,” said Waldron.
Positive Results
After three or four months of use, Excel Industries was impressed with the CMAXX Dust and Fume Collector. They saw a significant decrease in airborne smoke and particulate matter in the welding shop. In fact, environmental testing revealed a 30-40% reduction in aggregate particulate across the shop, with some areas experiencing a reduction of up to 150%. This improvement in air quality creates a healthier and more comfortable work environment for Excel’s welders.
Overall, Excel Industries’ experience with Imperial Systems’ dust collectors has been positive. The improved air quality has certainly led to a healthier work environment for employees, and the reduction in dust and particulate matter has likely contributed to increased efficiency. Likewise, if you are a manufacturer looking to improve your shop’s air quality and efficiency, Imperial Systems’ dust collectors are the best solution.
Arclabs Welding School in Columbia, South Carolina needed a weld fume extraction solution. They needed a system that could handle their current capacity as well as their future growth. They worked with Atlantic Dust Collection, an Imperial Systems representative, to find their ideal system.
Overcoming Limited Space
Arclabs Welding School was looking for a dust collection unit that could be installed outdoors. “Since we have limited space in the shop, we wanted the bulk of the equipment to sit outdoors. So, we wanted it built to last,” said Tana Holcomb, Campus Administrator. Imperial Systems’ recommendation was its flagship product, the CMAXX Dust & Fume Collector. The CMAXX is known for its durability, heavy-duty construction, and lifetime warranty.
Improved Air Quality Leads to a Safer Learning Environment
Brett Vaughn, Welding Instructor, shares the changes he has seen since the installation of the dust collector. “The students completely love having that filtration,” he says, describing how quickly the shop fills with smoke if someone forgets to turn the CMAXX on, and how quickly the fume is removed once the unit is running.
Arclabs opted for a 32-filter cartridge CMAXX unit with the capacity to handle not only their existing 40 welding booths but also an additional 20 booths planned for future expansion. This future-proof solution ensures clean air for the expanding school and supports community growth and education.
Safety and Health Benefits Appreciated by Everyone
The positive impact of the CMAXX unit goes beyond just eliminating smoke. Students like Dylan Seymour no longer experience respiratory issues after a long day at work. “It’s literally a night and day difference,” said Seymour. “I don’t go home and hack and wheeze anymore.”
Arclabs Welding School: A Model for Prioritizing Safety
Arclabs Welding School has seen significant improvement in air quality and safety achieved with the installation of the CMAXX Dust & Fume Collector. Brett Vaughn strongly believes in the investment the school made in instructor and student health. “In my opinion, that fume filtration system is probably the best thing this school has ever done.” Arclabs Welding School serves as a model for prioritizing the health and safety of its students and staff by implementing effective dust collection solutions. Learn more about Arclabs Welding School here.
Check out our video testimonial with Arclabs Welding School:
A Breath of Fresh Air: The Imperial Systems Solution 
