Ecogate: Fully Automated Dust Collection System
Smart Automation in Industrial Ventilation
Ecogate's On-Demand Control System for dust collection is a fully automated solution designed to enhance energy efficiency, extend equipment lifespan, and reduce labor costs. By intelligently adjusting airflow based on real-time demand, Ecogate significantly lowers electricity consumption, minimizes wear on dust collectors, and streamlines operations. This article outlines how Ecogate’s system functions, the advantages of full automation, and the impact of deploying Ecogate across multiple facilities.
How Ecogate’s Automated System Works
1. Workstation Activity Detection
Ecogate’s system starts with Workstation Activity Sensors, which detect when a workstation requires dust collection. For example, in a CNC saw, the sensor activates when the material holding arm is engaged—before cutting begins—ensuring timely gate operation and airflow adjustments.
2. Signal Transmission & Airflow Adjustment
The sensor output is sent to the gate processor.
The gate processor transmits the signal via Modbus to the greenBOX control unit.
The greenBOX calculates the necessary air volume (CFM), based on the design air volume set by engineer, and adjusts the fan speed accordingly via the Power Master VFD (Variable Frequency Drive).
Additional gates open as needed to maintain required transport air velocities.
3. Fan Speed & Dust Collector Control
The Power Master VFD adjusts the fan speed and initiates the dust collector start sequence via the START relay connected to the dust collector’s PLC.
The dust collector’s PLC continues to manage internal components such as the airlock, cleaning pump, and transport fan.
If shutdown is necessary, the VFD sends a STOP command to ensure a controlled system halt.
4. Error Handling & System Protection
In case of a dust collector error, the system automatically stops the main fan to prevent dust accumulation and production downtime.
The dust collector’s PLC OK/Error signal is connected to the VFD, ensuring immediate response to faults.
The Power of Full Automation
With Ecogate, the entire dust collection process is fully automated:
Workstations operate normally while Ecogate dynamically manages airflow.
If no workstations are active, the system automatically shuts down, preventing unnecessary energy use.
During breaks and shift changes, the system pauses to save energy and reduce noise.
VFD-controlled startups eliminate power surges, lowering peak energy costs.
Manual system operation is eliminated, saving labor costs and increasing efficiency.
Ecogate’s system is fully compliant with NFPA dust collection control standards.
Key Benefits of an Automated Ecogate System
Up to 66% electricity savings on fan operation.
Reduced dust collector wear and tear, extending equipment lifespan.
Longer filter life, reducing maintenance and replacement costs.
Quieter work environments, improving workplace conditions.
Eliminates manual operation, leading to substantial labor savings.
Corporate-Wide Impact: Scaling for Maximum Savings
For businesses with multiple facilities, deploying Ecogate at scale delivers significant financial and operational benefits.
Estimated Annual Savings from Existing Deployments:
$1,500,000 | in electricity savings from optimized fan operation. |
$280,000 | saved on dust collector filter replacements. |
$220,000 | saved through automatic start/stop labor and energy reductions. |
$2,000,000+ | Total annual savings |
✅ Capital cost avoidance: Existing dust collection systems can handle more workstations with the same infrastructure.
✅ Improved operational insights: Monthly utilization reports enable better resource planning.
Transforming Dust Collection with Intelligence
Instead of running extraction fans at full capacity all day—wasting energy and money—Ecogate’s intelligent system provides on-demand suction only where and when needed. This dynamic control reduces energy consumption by 60–70% while improving dust capture and compliance.
Get Started Today
Call 888-ECOGATE or contact us to learn how Ecogate’s automated dust collection system can transform your facility.
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