Dust Extraction Systems
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What Our Systems can do for you
Ecogate Dust Collection System
Does your dust collection system and exhaust ventilation make up for a large proportion of your electricity bill? Are dust and fume particles put into the air during your manufacturing process impacting the health and safety of your employees?
If the answer to both of those questions is yes, then the advanced Ecogate dust collection systems can help.
The Ecogate dust collection system can do so much more than help you save money on your electricity bill though. It can improve working conditions at your facility by reducing noise, while also reducing the environmental footprint of your operations. In addition, the detailed analysis and report function allows you to review your precise energy usage and make smarter decisions.
How Does an Ecogate System Save You Money?
Industrial extraction systems are one of the largest electricity consumers in factories, accounting for up to 35% of the electricity usage. In many cases, all extraction fans at each station operate from when the machines are turned on to when they are turned off.
So how do you save money with Ecogate? Ecogate’s on-demand model provides extraction only to machines that are currently in use.
This eliminates wasted energy, successfully saving you money on your electricity bill. On average Ecogate provides up to 68% of electricity savings for your fume extraction or dust collection system. Find out more about how the Ecogate system operates.
How is Ecogate Different to Traditional Dust Extraction?
Traditional dust extraction systems are always on, which makes them largely inefficient. With Ecogate extraction is provided only to machines that are on, cutting electricity usage in half as a result.
Committed to revolutionising industrial extraction, Ecogate provides cutting-edge solutions to suit your precise needs.
In addition to great savings, the Ecogate system offers multiple advantages over traditional dust extraction. Those include seamless integration with building automation, advanced calibration wizard, flexible software architecture, safe transport air velocities and more.
Industries We Supply Systems to
Current companies with an Ecogate system installed
The Stages of the
Ecogate Dust Collection System
The Ecogate Automatic Blast Gates are installed at each machine to control the supply of suction. Not all machines are utilised at all time, the blast gates only open to provide extraction if a machine is operating.
Our patented guillotine style blast gates are made for heavy industrial use and available in a zinc-plated or stainless steel body.
The Ecogate sensors determine when a machine is in active operation and requires dust control. There are multiple sensor options, each ideal for different types of applications.
When the machine is on and in use, the sensors send a signal to the Ecogate greenBOX controller. The controller opens and closes the blast gates at the machine every time it needs suction. This is done in real-time for all machines.
The automation even covers you during breaks or at the end of the day - when all machines are off, the system automatically turns off, saving you electricity.
The greenBOX controller is the brain of the Ecogate dust collection system. The greenBOX is available in three sizes depending on capacity:
• greenBOX 12 - suitable for smaller workshops;
• greenBOX NXT - for medium size operations;
• greenBOX MASTER - for the biggest factories.
All gates, sensors and the Variable Frequency Drive (VFD) are connected to the controller. The sensors send information to the greenBOX, which it uses to open/close the gates, while also communicating with the VFD.
The greenBOX in the illustration to the right is the greenBOX MASTER (right side).
Ecogate's Powermaster is a Variable Frequency Drive (VFD) designed to regulate the speed of the collector fans, maintaining the optimal amount of air volume based on workstation activity. Its second function is to maintain minimum airflow.
This is a crucial step in designing a safe and effective extraction system. Failing to maintain airflow could result in catastrophic consequences as it can allow dust to settle in the ducting, posing a real fire and explosive risk.
Varying the speed of the fan allows usage to drop by 30-40%. Since electricity usage varies with the cube of the air volume, this typically results in energy savings between 50% and 75% from the pre-installation baseline.
Having detailed data available 24/7 means you could make better decisions. Whether you're expanding your factory and need to know the current utilisation of machines or don't want to rely on operator feedback with maintenance departments, Ecogate Analytics provides you with substantial data to use.
For customers using the NXT or Master controller, additional value is generated from automatic data analytics. This provides you with easy access to information about your factory utilisation and the performance of your dust collection systems.
By using the collected data Ecogate’s automated system saves you money every year through reduced electricity usage.
What are the Key Benefits of Ecogate's
On-Demand Dust & Fume Collection
Ecogate moderates the power of all extraction fans in your facility in real-time, directing airflow exactly where it is most needed. This allows the system to provide each of your workstations with the right amount of airflow second by second and day by day. Discover all Ecogate's key benefits in more detail to find out it's the solution for you!
Electricity saved is money saved. Less air volume equals slower fan, which means less energy costs and ultimately more money in your pocket.
Ecogate starts your dust collector when work begins and turns it off at the end of the shift. It also collects insightful date of your machines and savings.
Dust that isn’t adequately removed is harmful to employee health and ultimately poses fire and explosion hazards. Ecogate can greatly help minimize these risks.
Ecogate optimizes your fan to support all current workstations and more. This means less unnecessary capital expenditures when expanding.
All of our products are designed for long-term use in tough industrial environments. Cheaper alternatives may end up costing more in replacements and repairs.
By significantly reducing the amount of electricity you use, Ecogate helps you reduce your environmental footprint.
Calculate your savings below
Results based on an average 20% reduction of fan speed.
Annual total based on 50 working weeks per year.
Energy Saving Dust Collection
Fume and dust collection and extraction is essential for the operation of industrial facilities such as factories, workshops or pharmaceutical labs. The problem, however, is that many of the systems available on the market don’t work as efficiently as they could do, resulting in high energy usage and operation costs. Ecogate provides energy-saving dust collection allowing you to utilise your system’s full potential and achieve great savings.
Contact the Ecogate team to get your tailored quote!
Have a question?
Read our FAQs
Is Ecogate Easy to Use?The Ecogate system is designed with the user in mind above everything else. All of our installed systems are fully automatic, so you as an user won’t need to change your operation to fit around the system. During the installation process we offer fully detailed inductions and user manuals. We can also train your employees on-site and offer remote support and training as well. Our smaller greenBOX®12 systems are often installed by users themselves based on a step-by-step guide provided by us. Larger systems can also be installed by customers or maintenance personnel, and we offer online installation training.
Does Ecogate Work on Smaller Systems?Yes, we have three levels of controllers. Our greenBOX®12 is designed for smaller scale operations such as individual workshops This is our most affordable option that allows you to control up to 12 gates on a single dust collection system. If your system grows beyond 12 in the future, you can link two greenBOX®12s to manage up to 24 gates for that same dust collection system. For the next size of the systems we have greenBOX® NXT (can handle up to 32 workstations/gates), and greenBOX® MASTER that can handle the largest systems.
Is Ecogate Cost Effective on Smaller Systems?Absolutely and our team will work with you to figure out if Ecogate makes sense for your operations. One of the first steps in our process is determining the viability of our system for your specific needs. If you are not using all workstations at the same time, you can use smaller dust collectors compared to a traditional system. This will allow you to not only save electricity, but also reduce noise in your workshop.
Can I Use My Existing Fan With an Ecogate System?If your fan was properly selected for your dust collecting system, you can use it with an Ecogate system. Before we install the Ecogate system we will check the fan curve to ensure that the fan can handle the required air volume and provide the necessary pressure to overcome all system pressure losses. In addition, we will also check if the fan motor is compatible with the variable frequency drive of Ecogate. The motor must have insulation class F or better, which means all fans produced in the last 25 years would be suitable.
How Can the Dust Collector be Automatically Started and Stopped?A traditional dust collecting system is started by the operator 15 minutes before the start of their shift and stopped 15 minutes after the shift ends. With the Ecogate system, the dust collector is started automatically on demand. The start and stop are still done by proper sequence as required by the manufacturer of the dust collector; the Ecogate system will just "press" the start and stop buttons as if it is done by a real person. If any error is detected by the dust collector PLC, the Ecogate system will know it through ENABLE input of the Power MASTER VFD. The proper startup, stop logic is handled by a virtual PLC inside the Power MASTER (we are using Adaptive Programming of the variable frequency drive). As a result of this you will save on labour, decrease the wear and tear of your dust collector, and cut down on your electricity costs by not operating dust collector motors when unnecessary.
What are key benefits of having an Ecogate system?Besides energy savings, there are a number of other benefits you will notice when you switch to the Ecogate system, including a safer and quieter work environment, fully automated system that requires less maintenance, longer filter bag life, data analytics on how your machines are being used and how your dust collection systems are performing and potential incentives from your local utility company! To read more about the many benefits of Ecogate, visit our key benefits page.
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