Why Ecogate's greenBOX is the Top Choice for Industrial Ventilation in 2023
The Future of Industrial Exhaust Ventilation
Industrial exhaust ventilation is a critical component of any factory, but it's often overlooked when it comes to energy efficiency. Despite the clear market need, major manufacturers in the US are not selling energy-saving, demand-responsive ventilation systems. This is where Ecogate comes in. We've just unveiled the 2023 greenBOX Nxt, the latest addition to our controller family, and it's set to revolutionize the industry. Let's take a closer look at this cutting-edge technology.
In this article
The Untapped Potential of Energy-Efficient On-Demand Ventilation
It's intriguing to note that despite the clear market need, many major industrial ventilation manufacturers in the US aren't offering energy-saving, demand-responsive ventilation systems. This gap might be due to the fact that these systems can extend the life of dust collector filters, a significant revenue source for these companies. While these firms are rolling out new energy-efficient technologies like efficient filter media, improved dust collectors, and ventilation fans, on-demand gated systems like ours can save up to a 25 times more electricity on fan operation.
Rather than viewing other systems as competitors, we see them as collaborators. We're united in our mission to enhance energy efficiency in dust, fume, and mist collection systems. However, it's unfortunate that only a small proportion of installed dust/fume/mist collection systems have adopted on-demand technologies, which could potentially save up to two-thirds of electricity costs on fan operation.
It's worth noting that promoting energy efficiency is three times more cost-effective than generating new renewable energy with associated storage. The industrial exhaust ventilation sector, characterized by the use of the factory's largest motors and continuous operation during shifts, offers a prime opportunity for significant energy savings.
It's crucial to understand that these potential savings are based on the immutable principles of the fan law (affinity law), not on unfounded claims of miraculous efficiencies. The real challenge lies not with businesses pursuing similar goals, but with those that continue to install traditional systems despite the availability of a far superior, energy-saving alternative. Now is the perfect time to join us in our quest for industrial energy efficiency!
The greenBOX Advantage: Superior Hardware and Software
The new greenBOX Nxt, along with our upcoming larger control units - the greenBOX Max and greenBOX Master, are equipped with the latest hardware, powered by the 12th and 13th generation of Intel processors. Coupled with our modern software (you can learn more about it here), this powerful combination enables us to manage multiple dust/fume/mist collection systems using a single control unit. Stay tuned for the launch of the greenBOX Max and greenBOX Master, which are built on the same platform and promise even more capabilities.
Comparing Industrial Ventilation Control Systems
Industrial Ventilation Control Systems | IVEC | Inteliair | Save System | Ecogate System |
Company | Hastings Air | CECO | Nederman | Ecogate |
Number of Systems Controlled by Single Control Unit | 1 | 1 | 1 | Unlimited* |
Number of Gates/Workstations | xxx | xx | xx | Unlimited* |
Number of Ventilation Systems | 1 | 1 | 1 | Unlimited* |
Approx. number of installations | xx | xx | xx | Unlimited* |
Air Velocity/Volume/Pressure Measurement at Gates (drops) | NO | NO | NO | YES |
Air Velocity Measurement at Duct Branches | NO | NO | NO | YES |
Precise (whole duct diameter) Air Velocity Measurement | NO | NO | NO | YES |
Closed Loop Air Volume Regulation | NO | NO | NO | YES |
Communication to Higher Level Control System | NO | NO | NO | YES |
Calibration Wizard (System & Fan Curve Measurement, Mapping) | NO | NO | NO | YES |
Cascading Fans, Fans in Parallel or Series, Lead & Backup Fans | NO | NO | NO | YES |
Heavy-duty 24V DC Gates with Limit Switches and Air Velocity/Volume Measurement | NO | NO | NO | YES |
Fulfills NFPA 664-20 (woodworking), and 652-19 (combustible dust) | NO | NO | NO | YES |
Granular system adjustments (special settings for wide belt sanders, automatic winter mode, and more) | NO | NO | NO | YES |
*Number of gates, workstations, systems, and Variable Frequency Drives (VFDs) is virtually unlimited by the software, but practically limited by size of power supply for the gates, and number of Modbus communication ports.
The greenBOX Nxt: Unmatched Performance at an Unbeatable Price
The Ecogate greenBOX Nxt is a powerhouse, capable of managing dust/fume/mist collection systems with up to 72 automatic gates for as many workstations. It can also control as many dust collection systems as there are linked workstations, which includes the ability to manage numerous Variable Frequency Drives (VFDs). Currently priced at $2,499, the greenBOX Nxt offers exceptional value, costing approximately three times less than competitor control systems that can only manage a single dust/fume/mist collection system. When it comes to managing multiple systems, the cost advantage of the greenBOX Nxt skyrockets, becoming ten times more cost-effective compared to other systems. This makes it a perfect choice for factories planning for future expansion, as it can easily accommodate additional systems and workstations. It's no wonder our initial inventory has already sold out!
While our software doesn't inherently limit the total number of workstations (automatic gates) and Variable Frequency Drives (fans) it can manage, practical constraints come into play due to the power supply capacity for the automatic gates and the number of Modbus ports available on each greenBOX model.
This is why we've engineered larger control units like the greenBOX Max, which can manage up to 144 gates (limited by power supply), and the greenBOX Master, capable of managing up to 288 gates (also limited by power supply). Built on the same software/hardware platform, we can create even larger control units, and systems can be configured as distributed systems.
Reliability Redefined: Introducing High-Performance Power Supply Redundancy
We're excited to unveil a new feature that enhances the reliability of our larger control units, the Max and Master models: a redundant power supply. With over twenty-five years of experience in implementing dust collection control systems, we've consistently exceeded industry standards for system reliability. However, we've noticed that power supply failures have been the most common issue affecting control units and gates.
To address this, we've designed a dual high-end redundant power supply system for our new larger control units, the greenBOX Max and Master. Each unit comes equipped with two identical top-of-the-line industrial power supplies. With an impressive 94% efficiency, active power factor correction, and a Mean Time Between Failures (MTBF) of 1 million hours, these systems showcase exceptional efficiency and durability.
The idea is simple: if one power supply fails, the other seamlessly takes over, ensuring uninterrupted operation. At the same time, the greenBOX notifies the local maintenance team to address the faulty power supply.
Some might question the need for such a high-end feature. However, consider the scale of our customers, which includes some of the largest factories in the woodworking and pharmaceutical industries. A production halt in these settings could lead to losses in the millions of dollars, or even require the disposal of entire batches if dust collection is disrupted mid-process in a pharmaceutical factory. Furthermore, with thousands of systems installed globally, even a small percentage of power supply failures can result in a significant number of compromised systems. Given these stakes, we believe our dual power supply approach is not just desirable, but essential.
What Is Not Measured Cannot Be Controlled
Many competing on-demand ventilation systems operate by maintaining a specific pressure in the main duct, facilitated by a pressure sensor connected to the Variable Frequency Drives (VFDs). However, this approach has a fundamental flaw. Let's illustrate this with a practical test: in a pressure-regulated system, seal off the main duct at some distance from the fan (you can temporarily disconnect the duct joint for this). Despite the blockage, the pressure-regulated system will still adjust the VFD speed to regulate the pressure in the remaining main duct, even though there's no airflow due to the closed main duct. This shows that the pressure-regulated system doesn't account for the resistance of the duct system, which changes when you close gates at inactive machines.
To better understand this, let's draw a parallel with electrical circuits. In an airflow system, pressure (in "wc) is equivalent to voltage (V) in an electrical circuit, while airflow (CFM) is similar to current (A). Both are closely linked with system resistance, whether it's in the duct or an electrical circuit. Pressure drives airflow, but the volume of airflow at a given pressure depends on the resistance of the duct system. Therefore, maintaining constant pressure doesn't guarantee the desired airflow as it's dependent on duct system resistance.
In essence, what isn't measured can't be controlled. That's why the Ecogate system measures the air velocity at the gates (workstations), branches, and in the main duct. This aligns with NFPA standards (National Fire Prevention Association), which mandate that control systems must ensure minimum airflow requirements (not minimal pressure requirements) throughout the entire duct system for safety reasons, as settled combustible dust can pose fire and explosion risks.
Some competitors choose to leave the end of the main duct open or install barometric dampers at the end of the main duct. While this might be beneficial for smaller systems, it doesn't guarantee the appropriate minimum airflow in the entire duct system under all operating conditions.
The Ecogate greenBOX can assign gates to any number of necessary duct branches, measure air velocity at the gates, calculate branch air velocity based on gate data, and gauge air velocity and volume in the main duct. The greenBOX control system will open as many gates on non-operating machinery as needed to meet the minimal airflow requirements in the entire duct system.
Heavy-duty 24V DC Gates with Limit Switches and Air Velocity/Volume Measurement
Did you know that most on-demand control system gates either don't have limit switches, or their limit switches aren't communicated to the control system? As a result, such a system (and the user) can never be sure if the gates are truly open or closed. This is a significant issue because an effective dust/fume collection system must always know the status of each gate to accurately adjust air velocity and volume. As I mentioned earlier, the resistance of the duct system depends on the number and location of open/closed gates.
Are you aware that some competing systems still use DIP switches (manual switches that might remind you of computer expansion cards from the last century) to change the gate addresses for communication with the control unit? This approach can slow down the installation process and easily cause confusion. Can you imagine the hassle if you mistakenly set a few DIP switches out of hundreds of gates? And the difficulty of correcting these errors by navigating a lift within the factory to reach the gates and adjust DIP switches under poor lighting conditions? The Ecogate greenBOX resolves this issue by automatically assigning communication addresses to the gates during gate discovery, saving both time and effort, and eliminating potential errors.
As mentioned earlier, Ecogate gates can measure air velocity, volume, and pressure. They also feature a contact output to indicate when a gate is open and ventilating, either for workstation PLC or for a simple indicator light. And with our latest patent, we're bringing even more useful features to our gates.
The Case Against Pneumatically Operated Gates
As we continue to make strides in industrial energy efficiency, it's crucial to reassess outdated systems. Surprisingly, some operations continue to use pneumatically operated gates, despite the presence of more cost-effective alternatives. These gates not only carry a higher price tag compared to gates powered by 24V DC electric motors, but they also lack durability and reliable open/closed limit switches, if they have any at all. Moreover, their installation costs are amplified due to the need for compressed air systems, on top of the standard electrical setup required for electrically operated gates.
The main disadvantage, however, lies in the ongoing operational costs of pneumatically operated gates. Their dependence on compressed air significantly increases their operational and maintenance costs, primarily due to the inherent risk of air leaks within the system. Given these factors, it's clear that unless there's a specific and compelling reason to use pneumatically operated gates, their use is not cost-effective.
By adopting more modern and efficient alternatives, such as gates powered by 24V DC electric motors, industries can not only cut down on initial and maintenance costs but also improve reliability and overall system performance. It's essential to prioritize cost-effectiveness and sustainability by transitioning away from pneumatically operated gates in the quest for industrial energy efficiency.
The Ecogate Advantage: Advanced Functionality
The Ecogate system is brimming with advanced features, including Closed Loop Regulation, Communication to Higher Level Control Systems (such as BAS, Process Control System), and a Calibration Wizard. You can delve deeper into the benefits of the Ecogate system here. These cutting-edge functionalities set us apart, as they are typically absent from competitor control systems.
The greenBOX Family: Unmatched Value and Performance
The greenBOX control unit family is a testament to Ecogate's unwavering dedication to superior engineering, providing our customers with an outstanding solution. We're confident that these control units, designed specifically for dust/fume/mist collection, offer cost-effectiveness and scalability that will empower factories of all sizes to implement energy-saving Ecogate systems. Experience savings of up to 66% on fan operations and additional savings on heating & cooling (where applicable). Our control system represents the apex of energy conservation technology, showcasing unrivaled efficiency that leads to a hundredfold or even greater reduction in electricity consumption compared to conventional systems.
In conclusion, the greenBOX family of control systems is outperforming competitors with its unparalleled value and performance. It's time to turn your airflow into a cash flow!
Q&A
Q: What is the future of industrial exhaust ventilation?
A: The future of industrial exhaust ventilation lies in energy-saving, demand-responsive ventilation systems like Ecogate's greenBOX Nxt, designed to significantly reduce electricity costs on fan operation.
Q: What is the 2023 greenBOX Nxt from Ecogate?
A: The 2023 greenBOX Nxt is an innovative control system designed to manage multiple dust/fume/mist collection systems efficiently, offering significant savings on electricity costs and surpassing traditional energy-efficient technologies.
Q: How does the greenBOX Nxt contribute to energy efficiency in factories?
A: The greenBOX Nxt contributes to energy efficiency by utilizing on-demand technology that can save up to two-thirds of electricity costs on fan operation, making it a cost-effective alternative to generating new renewable energy with associated storage.
Q: What is the advantage of using the greenBOX Nxt in my factory?
A: The greenBOX Nxt offers several advantages, such as managing multiple dust collection systems using a single control unit, significant electricity savings on fan operation, and the ability to easily accommodate additional systems and workstations, all at an unbeatable price.
Q: How does Ecogate ensure the reliability of its control units?
A: Ecogate ensures the reliability of its control units, such as the greenBOX Max and Master, by designing them with a dual high-end redundant power supply system. If one power supply fails, the other seamlessly takes over, ensuring uninterrupted operation.
Q: What sets Ecogate's control systems apart from the competition?
A: Ecogate's control systems, including the greenBOX Nxt, set themselves apart by their ability to measure air velocity at the gates (workstations), branches, and main duct. They are also built with advanced features such as Closed Loop Regulation and a Calibration Wizard, usually absent in competitor control systems.
Q: Why is the Ecogate system preferable over pneumatically operated gates?
A: The Ecogate system is preferable over pneumatically operated gates due to its cost-effectiveness. Pneumatically operated gates carry a higher price tag, lack durability and reliable open/closed limit switches, and their operational and maintenance costs are amplified due to the inherent risk of air leaks within the system.
Q: How much can I save on fan operation with the Ecogate system?
A: With the Ecogate system, you can experience savings of up to 66% on fan operations and additional savings on heating and cooling, where applicable.
Q: What is the greenBOX family of control systems?
A: The greenBOX family of control systems, including the greenBOX Nxt, Max, and Master, is Ecogate's range of advanced units designed to manage dust/fume/mist collection systems. These control systems offer cost-effectiveness, scalability, and superior energy conservation technology.
Q: How can Ecogate turn my airflow into cash flow?
A: Ecogate can turn your airflow into cash flow by reducing electricity consumption with its innovative greenBOX control systems, leading to significant cost savings and increased energy efficiency in your factory.
Author, Ales Litomisky
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