Hi All, We are building a new shop. We specialize in wholesale custom closet parts. We are also considering marketing our integrated Cam Software and CNC hardware. So this may also serve as our working showroom.
That being said, I am looking at this as an opportunity to design the most efficient shop for our needs. We are going to minimize and close in the production area.
Office on one end, warehouse in the center and production on the other end.
First thing I have always wanted to do is separate the noise and heat makers. Vac Pumps and Dust handler being the worst offenders. Our plan is to put them is sound insulated room next to the production room. Then we would have some doors to direct the heat outside in the summer or back into the production area in the winter. We have a Dantherm S750 (possibly upgrading to a S1000) and plan on purchasing the dump bin. This should make it easy to empty the dust bin by rolling it out of the room the picking up with forklift.
A seporate room for the screw compressor doing the same.
Second thing is to go with all LED lighting.
Anyone have any things they think would be innovative features for a new shop?
Specs: We currently process about 600 sheets a month and build about 400 drawer boxes. The plan is to build about 8000 sq ft with 1000 sq ft of office, 3000 sq ft production and 4000 sq ft warehouse. We have room to add on easily when the need arrives. Not sure how high to build as we need to heat that in the production area. The plan right now is a Morton Metal building. 60X135.
I would really like to hear any ideas to make sure I get it right.
For the lighting get with your power company to see what programs they have for lighting. They will likely subsidize the expense of the fixtures if you apply in advance.
I would do the same for the gas company if you have natural gas heat.
Call the utilities and invite them to meet with you in the planning stages. They have people that specifically do that. They can show you how to be efficient and what they will help pay for. It is more than you might think. You can't do it after the fact (in my state anyway).
I understand your concern about ceiling height but consider storage (pallet rack height) and resale.
Think hard about the compressor/vac pump room. Ours has thermostatically controlled fans and louvered vents that open based on the compressor room temperature. Opening the door may not be enough in a small room to keep it cool. Don't put dust collection and compressors in the same room.
Same thing with reclaiming the heat air must come out into the shop and back into the compressor room. Easy to do when building the building harder after the fact.
Plumbing the compressed air. Are you going black pipe, copper or aluminum? Running the pipe correctly is very important. A proper piping system reduces pressure drop and allows you to run the compressor(s) at a lower pressure.
You did not mention:
Fans on the side of the building to vent in the summer?
The dust collector should be outside.
Consider an awning where you take side load deliveries. Makes it nice for deliveries in the rain/snow. Networking to the shop, warehouse and office.
Power to the building?
Parking lot cement/asphalt.
Bathroom plan/capacity must be considered with regard to expansion. Hate to have to add baths if you expand the building more expensive.
Old file secure storage?
We just renovated a building and these are the thoughts that occur to me off the top of my head.
Good luck! enjoy the journey it can be a long one!
Thanks Bill. I have considered most of your points. As I start to pin them down I will ask for further advise.
I am curious about your recommendation to put the dust collector outside. I thought that if you keep the cfm to under 5000 that you were better off keeping it inside.
My current dilemma is Gas vs Eclectic heat in the manufacturing area. This is a fairly small area (3000 sq ft) going to be very well insulated. We only have 1000 sq ft of office. I know gas is more efficient, but we only use it about 4 months a year. There is a base cost of $18 per month for separate gas account. Essentially giving us a $216 per year credit for going all electric. I wonder if going all electric would be more cost effective overall?
We have faily mild winters in Charlotte.
This year we have not had winter. :-)
If you are building a building I would build for growth. If you do go with interior collection have a plan to move it outside should the need arise. Hopefully it does, that means you're growing.
You may be better with the collector inside. According to guidelines you are not supposed to hook a wide belt sander to it. Is that a problem?
I am not familiar with your business. Sounds like mostly nested routing and edgebanding?
We just moved and installed an outdoor collector. There are pluses and minuses.
-Easier to empty (we don't empty it, it goes directly into a dumpster)
-Filters self clean
-It takes up zero floor space.
-It can be significantly larger than 5,000 cfm
-Less daily maintenance, much less.
-Fan is after the filter
-Its a single system if one machine needs it, it must be on.
-It blows air back into the building that is ~ 15 degrees colder than when it went out in Michigan in winter
-I believe it will increase your electric bill over smaller interior collectors that can be turned on and off based on need.
- Its expensive up front.
As I said earlier make sure you don't do something with the layout of the building and the land that precludes you from moving it outside should it become necessary.
I have an S1000 10hp with dumper, great collector. I am holding on to it in case I have a need far away from our main collector. Probably a dumb idea, I likely will not need it.
I can't help you with the electric vs gas not a choice for me, gas is a must here.
UPDATE: At the last minute we found a building that will fit our needs perfectly.
We found an old mill just a mile away from the property we had under contract to build on.
Paying about 50% more but getting 4.5 times the space :-)
Will be able to rent out about 15,000 ft. leaving us with over 20,000 sq ft.
Fully sprinkled, lots of power,drive in doors, plenty of loading docks and lots of ventilating fans. Of course Zoned I2.
Owner is former NACAR driver that purchased it with a large tract of old mill properties. He, his son and family have slowly fixed it up mostly by themselves and used professionals when appropriate. Very down to earth guy who values doing thing right and with his own hands.
It has been a pleasure working with him.
Should be making the move sometime in May.
This is the 4th property we have had under contract. Different issues with each one. This one was worth the wait!
Bill, Our dust handling demands are just the edgebander (2mm pvc only) and 2 nested based CNCs. We have a vertical panel saw and chop saw that are used very infrequently.
We are planning to add the Nederman dump bin for the dust collector. At $3200 itís a bit pricy but the payback should be reasonable. No blowouts from bags not being installed properly. 50% increase in capacity and no cost of bags. Also has the beninfit of taking up less room in our dumpster by not having it bagged. Plenty of room to install outdoor unit when that time comes.
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