When a confidential manufacturing customer needed to modernize an aging dust collection system, they partnered with Feyen Zylstra to implement an automation and controls solution that would improve visibility, enhance safety, and reduce energy consumption. The existing system offered no fault diagnostics or fine control—it functioned strictly as an on/off system—making troubleshooting difficult and driving unnecessary energy use, particularly during machine downtime. 

FZ delivered a fully integrated automation and controls solution tailored to the operational needs of the plant and the specific requirements of the existing ductwork. Replacing a traditional motor starter with a variable frequency drive (VFD) allowed for precise control of the dust collector fan speed, providing greater flexibility while significantly reducing mechanical stress on the motor and blower components. The system was also designed for full visibility across the plant network, enabling operators and maintenance personnel to monitor status and diagnostics from anywhere within the facility. 

To further improve efficiency, the new control strategy automatically ramps the dust collector down—or shuts it off entirely—when the machines it serves are idle for a defined period of time. When production resumes, the system can be restarted directly from those machines. This approach ensures the dust collection system operates only when needed, delivering meaningful energy savings without compromising performance or responsiveness. 

As part of a complete design build delivery, Feyen Zylstra provided control system design, programming, HMI visualization, and safety integration. The project included a custom, non‑UL control panel that was designed and built in‑house, allowing for a layout optimized around the customer’s maintenance practices and long‑term serviceability. Safety was a key component of the solution, with emergency stop functionality implemented across the machine to support reliable and effective emergency shutdown. 

The system was built using an Allen‑Bradley CompactLogix Safety Controller, Allen‑Bradley PanelView Plus HMI, and an Allen‑Bradley PowerFlex 753 VFD, delivering a robust platform for safe operation, intuitive interaction, and detailed operational data. 

Following implementation, the customer realized improved reliability and uptime through enhanced diagnostics and runtime tracking. Maintenance can now be scheduled based on actual system usage rather than fixed intervals, reducing unnecessary service and minimizing the maintenance burden. The VFD‑based control strategy also places less stress on mechanical components, helping extend equipment life. 

Safety and visibility improvements were equally impactful. Plant‑wide emergency stops provide added confidence during operation, while improved data access allows the customer to track runtime and power consumption to support informed operational decisions. By adjusting fan speed based on real‑time demand and automatically reducing operation during idle periods, the system delivers measurable energy efficiency improvements. 

The success of the project was driven by close collaboration between FZ’s engineering, prefab, and electrical service teams, along with the customer’s maintenance staff. By engaging early and designing with long‑term maintenance in mind, the upgraded system was built to support reliable, efficient operation well beyond initial startup.