That’s the situation a large semiconductor manufacturer found itself in last year. The Arizona-based company, one of the nation’s largest manufacturers of semiconductors, operates a silicon carbide production facility in Hudson, New Hampshire—not far from our metal fabrication shop.
For the past few years, the facility has been “growing” silicon carbide, a move that gives it more control over its manufacturing supply chain. Silicon carbide is a key component in the production of semiconductors for electric vehicles, charging stations, and energy grids.
It also happens to be extremely messy.
Although the actual “growing” of this material is relatively mess-free, the “harvesting” of silicon carbide is a different story entirely. At first, the ultra-fine black carbon dust accumulating on walls, carpets, and the underside of drop-ceiling tiles went unnoticed. But as production ramped up, the mess became impossible to ignore.
It wasn’t just a housekeeping issue; this dust posed potential health risks to employees. Recognizing the severity of the situation, an employee familiar with Macy Industries’ reputation suggested contacting us to explore options for a custom dust collection system that would address the issue and ensure a safer environment for their team.
Step 1: Designing Custom Dust Collection Booths
Before we could begin designing a solution to this facility’s dust challenges, we needed to see the problem firsthand. Our team visited the silicon carbide production facility to meet their team and conduct an on-site evaluation. To ensure we fully understood the project’s scope, we also brought in a third-party expert with experience in this type of dust to help us develop our initial plans and select the right-sized equipment.
This project was unique in that our client wanted more than a dust collector and ductwork. They requested complete enclosures around each workstation, as well as articulating extraction arms that employees would use to collect the dust as they were unpackaging the grown material. The booths also needed to be maintained at negative pressure to prevent dust from escaping.
Macy Industries handled all aspects of the design process, producing CAD drawings and conducting iterative design reviews to meet the client’s specifications. And because we’re committed to going above and beyond for our clients, we even built a complete prototype of the dust collection booth in our metal fabrication shop!
Though not part of our usual process, we knew building a prototype would solve a few important challenges. First, it would prevent disruptions or downtime at our client’s facility during the design and development phase. Second, it would allow them to see and interact with the design, ensuring they had complete confidence in our proposed solution.
Step 2: Fabricating the Custom Dust Collection System
As a full-service metal fabrication shop, Macy Industries has the experience and equipment to produce all custom components in-house—from large ductwork to the booths to the physical stands that support the ductwork. Fabrication highlights included:
- Metalwork: The Macy team sheared, rolled, and welded large metal sheets.
- Pipe Assembly: Attaching angle iron rings to pipe ends simplified the process of bolting adjoining pipes together quickly.
- Ergonomic Workbenches: Adjustable-height tables with lifting legs accommodated workers of all sizes, enhancing comfort and productivity.
We also integrated fire protection equipment into the system to meet safety and compliance standards. These meticulous fabrication processes ensured the final product was robust, efficient, and tailored to the client’s unique needs.
Step 3: Full On-Site Installation
Over six weeks, we delivered and installed the custom dust collection system, which consisted of five aluminum and plexiglass enclosures, each measuring 10 feet wide, 10 feet long, and 8 feet tall. The process involved:
- Deliveries: Our team transported multiple truckloads of booths, tables, ductwork, fittings, and hardware to the site. We delivered the dust collector on a flatbed trailer and installed it with a crane and telehandler.
- Assembly: We assembled the collector, HEPA filter, ductwork, booths, and integrated fire protection equipment into the system.
Once the new system was up and running, our client’s black dust challenges were solved—and they were thrilled with the results. Their facility is now clean, the air quality is improved, and their employees benefit from a safer workspace. They were so impressed with the outcome that they approached Macy Industries for another custom sheet metal fabrication project!
Macy’s Hands-On Approach Sets the Standard in Dust Control
At Macy Industries, we believe every challenge is an opportunity to exceed expectations. From the initial site evaluation to the final installation, our team works closely with clients to design and deliver custom solutions that address their specific needs.
For over 50 years, we’ve partnered with industrial, commercial, and residential clients throughout New England. From dust collection systems to commercial countertops to custom industrial tanks, our team delivers custom sheet metal solutions that make a difference.
When you work with us, you’re not just getting a system—you’re getting a dedicated partner invested in your success.
Are you ready to learn more about our custom metal fabrication capabilities? Reach out today to explore how Macy Industries can help with your next project.