Investing in a Cleaner, Safer, More Efficient Cartridge Loading Process
Stormwater360 engaged with DUSTEX to deliver a fully automated, dust-free cartridge loading plant. Read Dustex case study HERE.
At the heart of every StormFilter™ system is the cartridge — a precisely engineered unit filled with specially selected media, including carbon, perlite, and zeolite, arranged in a two-section inner and outer chamber. Getting that media into each cartridge, in exactly the right configuration, consistently and at volume, has always been central to how we manufacture StormFilter™.
As demand for StormFilter™ has grown, so too has our commitment to producing it as efficiently, safely, and consistently as possible. That commitment led us to invest in a fully integrated, automated cartridge loading plant — designed and delivered in partnership with DUSTEX, Auckland-based industrial dust extraction and engineering specialists.
Filling Line for StormFilter™
Where We Started
For years, our cartridge loading process was entirely manual. Operators filled cartridges by hand, pouring bags of carbon, perlite, and zeolite directly into each unit. Media was blended in a concrete mixer in small batches, and a containment tent was set up within the factory to manage the dust this process generated. That tent, combined with respiratory and eye protection for our operators, was an effective interim control — but the work itself was physically demanding, and it typically took three people to keep the loading operation running.
As our production volumes grew, this manual process increasingly became an operational bottleneck. The concrete mixer limited batch size and consistency, and we recognised an opportunity to redesign the entire process — not just to manage dust more effectively, but to support future production volumes, improve product consistency, and create a safer, better working environment for our manufacturing team.
Our first conversation with DUSTEX about this challenge actually goes back to 2017, when their team visited our site to discuss dust extraction options for a proposed cartridge loading plant. At the time, we were still weighing up our options and no project went ahead immediately — but that early conversation planted a seed that would eventually grow into something much bigger.
Why We Went Turnkey
When we returned to DUSTEX in 2025, our brief had grown substantially — from a standalone dust collector to a full turnkey solution. Working closely with the DUSTEX team, we defined the scope together: a purpose-built cartridge loading plant that would automate our process from end to end, within a defined budget.
Rather than retrofitting dust control onto our existing setup, we wanted dust extraction designed into the system from the very beginning — at every stage where it was actually needed. This approach meant we could remove most manual and dust-generating touchpoints entirely, rather than simply finding better ways to manage them.
Dust Extraction for Filling Line
What We Built, Together
DUSTEX designed, supplied, and commissioned our complete turnkey dust extraction system and cartridge loading plant, delivered in February 2026.
The new system replaced virtually every step of our previous manual process:
Bulk media handling: We replaced the concrete mixer and bag-pouring operation with large hoppers fed by bulk bags. A forklift positions the bulk bag above the hopper, the bag opens at the base, and the media flows straight in — substantially reducing manual lifting, small-batch handling, and mess.
Blending: A dedicated industrial blender replaced our old concrete mixer, blending carbon and perlite to the required ratio in consistent, full-scale batches every time.
Automated filling: Vibrating feeders now draw the blended media from the hoppers and feed it into the cartridge chambers in the correct configuration — automatically delivering the right material to both the inner core and outer layer of each cartridge.
Compaction and conveying: A vibrating table compacts the media as it loads, ensuring consistent fill density across every cartridge. Once filled, cartridges move along a conveyor to the next stage of production.
Dust extraction, integrated throughout: Dust extraction is now built into the system at every point where it's generated — the blender, the vibrating feeders, and the filling stations. Airborne particles are captured at the source and extracted away, creating a significantly cleaner working environment without needing a containment tent at all.
We also included an overhead crane in the plant design, giving our operators a safe, efficient way to lift and position cartridges and bulk bags.
The Difference It's Made
The contrast between our old process and our new one is striking. What once required three operators working inside a dust containment tent — manually pouring bags, running a concrete mixer, and wearing respiratory and eye protection throughout — is now a clean, efficient, single-operator plant. One person can run our entire cartridge loading process, without a dust tent, with substantially less manual lifting and significantly reduced exposure to airborne media.
The new plant has drawn strong praise from both our management team and, most importantly, from the operators who run it every day. For the people on our factory floor, the improvement is immediate and tangible: the work is less physically demanding, the environment is cleaner and more comfortable, and the process runs faster and more consistently than it ever did before.
Our relationship with DUSTEX now spans more than eight years — from that first site visit in 2017 to the delivery and commissioning of our completed plant in February 2026. It's a great example of what a long-term partnership, genuine collaboration at every stage, and a shared commitment to getting it right can deliver: a real, measurable improvement in productivity, product consistency, and operator experience.
In Our Own Words
We engaged with DUSTEX initially for a dust extraction solution forming part of a filling line we were looking to develop. We soon realised DUSTEX had the skills and expertise we required for a complete turnkey solution far exceeding the initial blueprint.
DUSTEX took a collaborative approach, working closely with our operations and engineering teams to create initial drawings which were refined, developed, and produced. The project was managed with full installation, no hassle, and very little downtime.
The outcome is a filling line we're proud of — a safer and more pleasant working environment, with both reduced dust and reduced manual lifting, and superior product flow. It has also improved our filling quality while adding capacity.
I have no hesitation in recommending the DUSTEX team."
— Miles Henderson, Global Operations Manager, Stormwater360
This investment reflects our ongoing commitment to manufacturing StormFilter™ to the highest standard — not just in the performance of the product itself, but in how safely, consistently, and efficiently we bring it to life for engineers and councils across New Zealand.
StormFilter™ Filling Line