Fetzer Woodworking: Embracing Efficiency with Ecogate's On-Demand Dust Collection
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About Fetzer
Founded in 1909, Fetzer Architectural Woodwork has grown from a small cabinet shop in Salt Lake City to become one of the largest architectural millwork companies in the United States. Now in its fourth generation of family leadership with Erik Fetzer at the helm and fifth-generation members joining the ranks, Fetzer continues to push the boundaries of architectural woodwork. Their expertise spans a wide range of projects, from retail stores and restaurants to hotels, airports, and corporate offices. Fetzer's commitment to innovation and craftsmanship has made them a leader in the industry, with their work found around the world, from high-end retail stores in global capitals to significant local projects like the Salt Lake City International Airport.
The Challenge: Inefficient Dust Collection
Like many woodworking facilities, Fetzer struggled with the inefficiencies of traditional dust collection systems. Their dust collectors ran at full speed 24/7, consuming energy even when only a single shop saw was in operation. This inefficiency was a constant drain on resources and operational costs.
Erik Fetzer had been aware of Ecogate's innovative solution since spotting it at IWF around 2004. While the value was immediately apparent, the timing and scale weren't right for implementation at that point.
The Catalyst for Change
A decade later, increased production demands led Fetzer to expand into a second 90,000 square foot facility, adding to their existing 133,000 square foot main building. This expansion came with its own 90 HP motor for dust collection, further increasing energy consumption.
When circumstances led to the consolidation of operations back into the main facility, Fetzer faced a pivotal decision. The prospect of relocating 45,000 square feet of equipment was daunting, but it also presented an opportunity for optimization.
Ecogate's Solution
Fetzer revisited the Ecogate option, aligning with their policy of investing in equipment with an ROI of 1-3 years. Ecogate conducted a comprehensive assessment, calculating CFM requirements for each machine and branch of the dust collection system.
Despite initial concerns from the Operations Manager about maintaining proper suction, Ecogate's analysis of expected Workstation Active Utilization demonstrated that the system's dynamic capacity would ensure minimum conveying velocities and appropriate drop air velocities.
Implementation and Immediate Results
Fetzer used the proceeds from selling their second building to overhaul their entire dust collection system. Ecogate was integral to this process, connecting both collectors to a single greenBOX Master controller.
The results were immediate and impressive:
Within the first week, the system was running at 70% capacity, with noticeable savings.
Utilization would at times drop to as low as 25%, allowing for maximum energy savings.
Two months post-installation, energy costs dropped from $32,000 to $22,000 per month, resulting in $10,000 monthly savings.
Efficiency and Automation Benefits
The Ecogate system solved longstanding issues with manual adjustments to capture velocity, which had previously led to compromised product quality due to excessive suction. The new system automatically optimized suction levels.
Fetzer appreciates the "set and forget" nature of the Ecogate system, requiring minimal oversight. They now only check the system a few times a year, mainly when making system changes.
An unexpected but welcomed benefit was the automation of the dust collector operation. No longer needing to manually turn the system on and off daily has saved significant time and effort over the years.
Long-Term Satisfaction
Fetzer has been enjoying these benefits for over 15 years. While they've reached maximum capacity in terms of machine count, they continue to optimize their setup by upgrading machines one by one, further increasing efficiency and savings.
Erik Fetzer summed up their experience: "I have always loved the product and now that we own it, we love it even more."
Conclusion
Fetzer Woodworking's journey with Ecogate's on-demand dust collection system showcases the long-term benefits of embracing innovative technology. From significant energy savings to improved operational efficiency, the implementation has proven to be a pivotal decision in Fetzer's continued success and sustainability efforts.
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