What is the ECOGATE System and how does it work?
The ECOGATE System is a microprocessor-controlled extraction optimisation system, employing a central control unit – the greenBOX® – which constantly monitors the operation of individual machines.
In many manufacturing facilities, as little as 50% of dust or fume-creating machinery may be in operation at any given time, but extraction plant usually runs at full capacity, with fixed fan speed, all of the time. The result is an extraction system which is likely to be consuming more electricity than all the lights and all the machinery put together. The ECOGATE System solves that problem by automatically closing ports to non-operating machines, and by regulating the speed of the extraction fan accordingly.
When a production machine is turned on, a remote sensor signals the control unit to open a motorised gate and provide extraction for that particular machine. The controller then determines the optimum fan speed, which is achieved using variable speed technology. When the machine is turned off, the gate automatically closes and fan speed is again adjusted accordingly. This means that you only use power when you need it. The system is also designed to maintain minimum airflow in the duct system, by opening additional gates when necessary, delivering good system balance and preventing dust settling in the duct system.
The result is an optimised system that only uses energy when required. Installing the proven ECOGATE ‘Extraction-on-Demand’ system will slash electricity bills by up to 80% (with an average of 62%) and will typically pay for itself in just two years.
Benefits of installing the ECOGATE System
- Energy savings can pay for a system in less than 2 years.,/
- Remote access system status and statistics with Ecogate DataMiningTM.
- Workshops can be expanded without the need for additional fans or ducting.
- Noise at the fan and inside the workshop is significantly reduced.
- Reduced maintenance and increased lifetime for fans.
- Possible integration with other control systems to allow auto-start or shutdown of fans, and on-demand opening/closing of all gates for cleaning and maintenance.
- Easy route to help larger companies meet their CRC needs. Read more
Why does it work?
Just for a change, the laws of physics are on our side! Fan speed and extraction volume are directly proportional; if you vary the fan speed, the volume changes by the same percentage.
However, the relationship between volume and power is cubic³, which means a relatively small change in volume gives a much larger change in power consumption - reducing fan speed by 20% reduces power consumption by nearly 50%.
Is the system right for my workshop?
ECOGATE offers total design flexibility – whether it’s a dust or fume extraction system serving two or three machines, or a large manufacturing facility with a plethora of dust-creating machinery, the Ecogate system offers a cost-effective solution.
ECOGATE offers a choice of control systems: The greenBOX 12+ controller is designed for workshops with one main extraction fan and up to 12 workstations. The greenBOX 12+ can be serialised, working in tandem to control up to 24 machines.
For larger manufacturing facilities, the greenBOX MASTER SRL is capable of controlling up to 4 extraction fans, handling as many as 200 workstations.
System monitoring and energy-saving evaluation is provided via a server-based solution; DataMiningTM is available on an annual subscription basis, and includes unlimited software updates and remote system check-up.
Operated by a 24V DC geared motor, motorised ‘ECOGATES’ are an integral component of the system. Available to suit a wide range of ducting sizes, they are fabricated in zinc-plated metal or stainless steel.
The gates are activated via ECOGATE Volt Sensors which detect changes in voltage when a machine is turned on or off. The ECOGATE sensors read any AC or DC voltage.
What’s the track record?
The proven, cost-effective ECOGATE system has been improving the control and energy-efficiency of dust extraction equipment worldwide for over ten years, and there are hundreds of installations in place, with over 20,000 ‘ECOGATES’ currently in use.