December: Finished Installations in Europe, installation progress in US, new order for Oakland Museum, CA
Midway through December 2004, five Ecogate MASTER Systems where installed and operational at SAPELI, Polna, Czech Republic ( www.sapeli.cz ). Three systems are 37 kW, one system is 45 kW, and one system is 55 kW. All in all, 70 energy-saving Ecogates are used.
The installation of three Ecogate MASTER Systems at Kasalova Pila, Jindrichuv Hradec, Czech Republic (www.kasalovapila.cz ) is finished. Mr. Fisher, the production manager, told us in a telephone interview that he is impressed because while initial project data for the Ecogate Master system indicated potential savings of 56%, the actual "measured" savings have ranged from 65% to 72%. Another surprise benefit according to Mr. Fisher is the impact of reduced electricity consumption. Their main transformer was at its threshold capacity, but because of the reduction in the consumption of electricity with the new Ecogate system, there is actually enough capacity to add an additional piece of equipment before expensive changes are required.
Installations of Ecogate MASTER systems are continuing at Drees Woodwork, CA (two 300 HP MASTER systems) and Masonite, Tampa Florida (one MASTER system). Ecogate distributor NORDFAB received a new MASTER system order from Oakland museum in California.
November: greenBOX (eight channel model) NEW function for larger motorized gates
GreenBOX (eight channel model) now supports connection of larger motorized gates. Description: The new function allows setting independent opening/closing time separately for each gate (each channel). This function will allow connecting of 4", 5", 6", 7" and 8" gates to the greenBOX unit. Details: Opening/closing time varies according to gate diameter. For example, the proper open/close time for a 4" gate is shorter than that for a larger gate. In the past, to accommodate the proper open/close times for larger gates, one needed to set the longest necessary time for all gates. Now, all gates can have their own proper open/close time settings. All new orders will be shipped with this new firmware, while an upgrade is available for existing users; please contact Ecogate for details.
November: greenBOX PRO (22- channel model) safety function is now user selectable
Safety function is now selectable by request of existing users. If this function is turned ON, then when all workstations are not working and the dust collector stops, all gates will go to the open position. This function helps to save the duct system from high negative pressure if the fan is switched on manually by accident. On the other hand, this function slows down the startup of the system because when you start the first workstation, the greenBOX will start the dust collector and then close all non operating gates one by one (except gates that were initially open), and this takes a relatively long time. So if you are sure that negative pressure in your system cannot destroy ducting, you can switch this function off for faster system startup. All new orders will be shipped with this new firmware, while an upgrade is available for existing users; please contact Ecogate for details.
November: New reports available in Ecogate DataMining software version 3.1
The chart below is a report from real factory from our DataMining software about how many workstations (out of 36) are running during what percent of time; for example, for 12.99% of time (shift time), two workstation are running. The probability of more than 28 workstations (total number of workstations connected to system is 36) running at the same time is close to zero, ergo it is possible to design a smaller system or use more workstations in an existing system: The chart below is a report from real factory from our DataMining software about how many workstations (out of 36) are running during what percent of time; for example, for 12.99% of time (shift time), two workstation are running. The probability of more than 28 workstations (total number of workstations connected to system is 36) running at the same time is close to zero, ergo it is possible to design a smaller system or use more workstations in an existing system:
This chart shows the activity of workstations during a 24 hour period. The first peak is the first shift, the second (smaller) peak is the second shift.
October: New Installations in Czech Republic, Europe
According the Oto Hofman, Ecogate European dealer Hofmans Company began installing the first eight energy saving Ecogate MASTER Systems in Europe. Three of these systems will be installed in Kasalova Pila, Czech Republic and five of them will be installed in SAPELI, Czech Republic.
Kasalova Pila, Jindrichuv Hradec, Czech Republic (www.kasalovapila.cz) is a European quality award-winning producer of high-end doors and windows. The company has already been using two Ecogate PRO Systems for several months. With the new order, installation is already underway and the new systems will be operational by the end of October 2004.
Midway through November 2004, 5 Ecogate MASTER Systems will installed and operational at SAPELI, Polna, Czech Republic (www.sapeli.cz). Three systems will be 37 kW, one system will be 45 kW, and one system will be 55 kW. All in all, 70 energy-saving Ecogates will be used. We hope that these new installations will start a wave of interest in Ecogate systems throughout Europe.
September: New Version of the Ecogate Duct Optimizer Software
The Ecogate Duct Optimizer software attracted much attention from industrial ventilation companies at the 2004 IWF show in Atlanta, GA. The software is used to calculate optimal ducting layouts for industrial ventilation systems. The latest version includes new features such as calculations using static pressure balancing in the whole duct system, user-input fan efficiency and motor efficiency, losses in clean & dirty filter and return air losses. The software also includes system simulation with the use of Ecogates. A typical improvement in Static Pressure Losses is 20% compared with classically designed systems. While this is a relatively small difference in Static Pressure Losses, our calculations indicate that system operation expenses are several hundred thousands dollars lower as compared to a typically designed system with two systems of 300 HP (over twenty years, which is the typical life span of a system). Duct Optimizer is already being used for real system calculations, for example for Patrick Industry in Indiana, other projects are underway in Europe.
August: Installation at Kolbe & Kolbe successfully finished
Ecogate dealer Koger Air finished the installation of two Master Systems for Kolbe & Kolbe Millwork, Inc. ( http://www.kolbe-kolbe.com/aboutus_history.shtml , Kolbe & Kolbe Millwork Co., Inc., 1323 S. 11th Ave., Wausau, WI 54401-5998) renowned producer of quality doors and windows. The new, fourth generation system was installed, including Ecogate DataMining software for plant work efficiency monitoring. Projected electricity saving is 74% (890,985 kWh annual savings).
August: New Order from Masonite International
Ecogate dealer EnergyEcon received a new order from Masonite International Corporation (5110 W. Clifton St., Tampa, Florida 33634, (813) 884-3456, http://www.masonite.com/ ). This order is based on a general agreement to which other factories can be added. The contract is using the new payment option Paid-By-Electricity-Savings, which includes no down-payment, and monthly payments lower than the electricity savings cost. This program has been developed by EnergyEcon and is available to all Ecogate Dealers, whose customers qualify for the program. The installation of the first system is scheduled at the end of September 2004.
August: The Chinese Patent
Last week Ecogate received the original Chinese patent for the Ecogate System, which guarantees the legal protection of the system for twenty years. We consider this very important because growing numbers of production using industrial ventilation are being transferred to China recently. Energy saving technologies for industrial ventilation appear significant, for electricity costs make up to 30% of total production costs in China. Electricity supply in China is limited and some factories have to close for up to nine days a month due the lack of electricity.
July: New order from Drees Wood Product Inc., California
The order has been placed by A.T. Mitchell Machinery, a dealer of Ecogate. Two large Ecogate Master Systems, each 300 HP will be delivered. This is the second Drees Wood Products, Inc. factory that will use Ecogate energy saving systems. Drees Wood Products ( http://www.dreeswoodproducts.com/ , see products at http://www.larsonimages.com/html/swd2.html ) produces a multitude of different kitchen cabinets doors. The latest generation of the Ecogate system will be delivered, including "DataMining" software for Real-Time plant activity monitoring.
July: IWF 2004 Atlanta Show
Visit Ecogate and NORDFAB on their joint booth at the IWF 2004 Atlanta Show August 26 through 29 at booth 4613, building B1 (see also our Challengers Award entry, "Real-Time Factory Efficiency Monitoring" at www.iwf2004.com ). The booth will include a real-time simulation of an industrial ventilation system with the Ecogate System installed, which will show and explain the functions of the PRO and MASTER Ecogate Systems. It will also show actual air volume and electricity savings on a computer screen. Additionally, the booth will showcase the new generations of all of the Ecogate Systems. Bring along a list of your workstations and diameter of the drops and we will calculate your potential savings and return investment for free during the show!
June: NORDFAB west coast dealer training
June 22 - June 24; Hotel Mirage; Las Vegas
As part of the NORDFAB University in Las Vegas, a training session for NORDFAB west coast dealers for sales of the Ecogate system took place June 22 - June 24 in the Hotel Mirage in Las Vegas. At the beginning, Niels Pedersen President of DISA USA and Tom Ballus, the NORDFAB National Sales Manager, welcomed the participants and explained Ecogate Systems sales strategies. The training itself was led by Bob Bolling, the NORDFAB-Ecogate sales engineer. We believe that the tens of newly trained dealers will help to bring a sales boost to the west coast.
June: Next Generation of ECOGATE Systems
Our efforts now are focused on the introduction of a new generation of ECOGATE Systems to the market. Next MASTER Systems for Kolbe & Kolbe, Patrick Industry in Indiana and PRO systems for Wellborn Forrest, and Kasalova Pila (Czech Republic) will be delivered as the new generation of ECOGATE Systems. Also a new version of greenBOX ONE will be delivered shortly to customers.
1. ECOGATE greenBOX MASTER
ECOGATE MASTER System for industrial producers is the most important ECOGATE product achieving the highest electricity savings (in average on all installed systems 68%, and up to 80% on new systems) and generating about 80 percent of our sales.
Objective of the new generation of ECOGATE Systems is further reduction of product and installation costs to make return on investment shorter, a more user-friendly software user interface, and overall better efficiency of industrial ventilation systems. These changes are other "small" steps in our pursuit of a perfect system, to make the ECOGATE systems affordable for every customer, and to define ECOGATE as the "industry standard".
The most visible upgrade is the better, larger graphical display with high resolution and high contrast colors. Even more importantly, it is now possible to update the control pages from CompactFlash card (formerly it was possible only by using a PC with special and costly development software). From now on, this color display will be delivered with all greenBOX MASTER models (formerly smaller greenBOX models where using small black & white displays). Another exciting possibility of this display includes connectivity to the Ethernet network, which will enable in future to connect our systems to corporate computer network (LAN). At the same time, a new version of the greenBOX firmware with other improvements will be delivered.
Using more sophisticated technology in our systems means more user-friendly "face" of the system for customers and more automated set-up procedures for system installers, as well as easier maintenance of the systems. Firmware improvements include better warning and error indication. For the first time, all gates in the system are monitored and warnings and errors are recorded and indicated.
The more complete warning and error status is also implemented in the new version of ECOGATE DataMining software, as well as in the new, improved, much faster SQL database engine. New, semi automated system set-up procedure will be included shortly. Setup system measurements are now recorded on the CompactFlash card for future references and for system fine tuning.
New generation of greenBOX MASTER control computer
2. ECOGATE Power MASTER Unit
For our Power MASTER unit, we have redesigned the electronic interface board (formerly two boards are now consolidated in one board only). Among the improvements are:
First, programming of the variable speed drive is now possible during the by-pass operation (for easier service and maintenance).
Second, "Input enable signal" is now indicated on the front door (absence of "input enable" signal was causing some additional service calls).
Third, ECOGATE Power MASTER enclosure is now redesigned for better protection against sawdust. Cooling air inlets are now equipped with replaceable filters.
Fourth, Electronic boards are now protected by differential current protector (better overload protection).
The good news for our customers is all these improvements are made without any additional cost to the system; it is due to improved design and higher production efficiency. New User Guide and Connection Sheets will be available in a few weeks.
New generation of Power MASTER control computer
3 . ECOGATE ECOde sensors
Sensors are the inevitable "front-end" part of the system. New version 3 offers improved tolerance to industrial interferences and to voltage peaks. Input now works with wider range of input signals, so setting is usually not necessary and installation is faster and more cost effective. Indication is also improved; these LED indicators are included: Power, Signal, Gate opening, Gate closing. This new PCB also supports connectivity to any standard industrial sensor (limit switch, beam sensor, dry contact from CNC or PLC). New connection sheet is already available.
4. ECOGATE greenBOX ONE
Version 3 of the greenBOX ONE is about 30 percent smaller in size but more sophisticated. The most important improvement is that user settings for different gate diameters are no longer necessary. Other improvement is better status indication (Power, Gate opening, Gate closing, and sensor Signal). The user can select from two values of ON delay and two values of OFF delay. The unit is now using the external power supply adapter (UL listed transformer, 115V AC with output 18V AC). Industrial standard 24V DC power supply is also supported. New brochure and new User guide are already available. The greenBOX ONE is designed for one workstation with up to 2 gates to increase ventilation system capacity and save electricity without the expense of making the system bigger.
New generation of greenBOX ONE control unit
5. ECOGATE greenBOX PRO
As we have mentioned earlier, the most important improvement of the GreenBOX PRO is its connectivity to Windows PC. The new "ECOGATE greenBOX PRO Setup and Monitoring" software on CD and serial cable are delivered for free with every system. The greenBOX PRO firmware is now possible to update from our Windows software (formerly it was possible only from PC by using special and costly development software). The greenBOX PRO is designed for medium size factories with up to 22 workstations to increase ventilation system capacity and save electricity without the expense of making system bigger. New brochure, Connection Sheets and new User Guide are already available.
New generation of greenBOX PRO control computer
We are convinced that our dealers, installers and customers will agree that these changes better our systems and that we are making progress in our pursuit of perfect systems, to make the ECOGATE Systems affordable for every customer, and to define ECOGATE as the "industry standard".
May: Ecogate will be presented at the major European woodworking show XYLEXPO in Milan, Italy
Ecogate will be presented at the major European woodworking exhibition XYLEXPO 2004 held in Milan, Italy, from May 26 th to May 30 th . Ecogate systems will be exhibited at Milan Fair Grounds, Hall 11, Booth C12, together with a renowned woodworking machinery producer NEVA Kardasova Recice, Czech Republic ( www.neva.cz ).
According to Oto Hofman, sales manager of European Ecogate dealer, the latest generation of electronic energy saving gates for industrial ventilation systems and the newest generation of Ecogate Master Systems including the DataMining software for real time workstation activity monitoring will be presented. DataMining is a significant tool for corporate headquarters: key decisions can now be based on exact real data (past and current) about plant performance and operations efficiency. Selected European woodworking producers have been invited to the show. We are expecting that Ecogate dealer will sign during this show an important contract for sale of five Ecogate MASTER Systems to SAPELI, Jihlava, Czech Republic, ( www.sapeli.cz ).
A second contract is prepared to be signed with Kasalova pila, Jindrichuv Hradec, Czech Republic, ( www.kasalovapila.cz ), the sale of two Ecogate PRO Systems. Kasalova pila is a European quality award winning producer of high end doors and windows. We are hopeful that these activities will start a wave of interest in Ecogate systems in Europe.
May: New order from Patrick Industry, Indiana.
The order has been placed by EnergyEcon, a dealer of Ecogate. Ecogate Master System 100 HP and Ecogate greenBOX ONE for 60 HP systems will be delivered. This is the third Patrick Industry factory that will use Ecogate energy saving technology, other two are in their California and Oregon plants. For the first time new software Ecogate Duct Optimizer was used to design optimal system by using scientific simulation and optimization. Patrick Industries produces a multitude of different manufactured products from their 15 manufacturing divisions, which include: make-to-order laminated products using vinyl, paper, veneers and high pressure laminates (HPL) to various substrate materials using the latest in lamination technology. The latest generation of the Ecogate system will be delivered, including "DataMining" software for Real-Time plant activity monitoring.
May: New Ecogate MASTER System order
We received a new order from our dealer Koger Air for two Ecogate MASTER Systems, 150 HP each. Systems are for Kolbe & Kolbe Millwork, Inc. ( http://www.kolbe-kolbe.com/aboutus_history.shtml , Kolbe & Kolbe Millwork Co., Inc., 1323 S. 11th Ave., Wausau, WI 54401-5998) renowned producer of quality door and windows. The latest generation of the Ecogate system will be delivered including DataMining software for Real-Time Plant Activity monitoring; this important tool will give management feedback and help them to understand and monitor production. The Systems will also be delivered with our new LCD display with higher graphical resolution and corporate LAN connectivity (Ethernet). The new Power MASTER unit is also upgraded (INPUT ENABLE is now indicated on front panel; variable speed drive can be now programmed in BYPASS mode and more.). Projected electricity saving is 74% (890,985 kWh annual savings).
New Ecogate PRO System order
DISA USA will install the new Ecogate PRO System at Wellborn Forest ( http://www.wellbornforest.com/ , 2212 Airport Blvd., Alexander City, AL 35010, 256-234-7900), producer of fine kitchen and bath cabinetry. The Ecogate PRO system (for up to 22 workstations) was recently upgraded. This new generation will support setup and system monitoring on Windows PC via serial channel (desktop or notebook models). This option will shorter installation and system setup and will allow management to monitor workstation operation in real time on windows PC.
April
New firmware version 3.13 for greenBOX MASTER (all models) is now available. Most important improvement is automatic time adjustment for daylight savings and other minor new features.
New R&D
Soon will be available second generation of Ecogate PRO system for medium sized factories (up to 22 workstations), new generation will support setup and system monitoring via Windows PC equipped by the serial channel (desktop or notebook models).
April
New Ecogate MASTER Installations: system installations were completed by EnergyEcon for Patrick Industries in Oregon (incentive 55% of project cost was approved by the power company in Oregon; results are 60 % savings during first shift, 70% during second and third shift) and Sauder Woodworking in Michigan (installation was done by their maintenance department; first ECOGATE MASTER system; they have a total of 32 250 HP dust collecting systems in one location).
We are also preparing the first projects in Europe, the Czech Republic, for a successful mid-size woodworking company "Kasalova Pila s.r.o." (www.kasalovapila.cz). Kasalova Pila was awarded by XI. European Quality Prize in Paris. Several other projects are under way in the U.S.A. and Mexico (in cooperation with Ergon Plus Ingeniera).
March
Glendale, CA, Thomasville, NC - March 1, 2004 - Ecogate, Inc., manufacturer of the electronic control system for industrial ventilation, and Nordfab, the nation's oldest and largest producer of clamp-together ducting for dust collection, today announced a strategic partnership where Nordfab will become the sole distributor of Ecogate Systems in the Americas, and DISA will be responsible for sale in Europe and Asia.
Over the last 5 years, Ecogate has developed, installed, tested and perfected a highly technical system combining automatic blast gates, PLC controllers and even fan motor inverters to maintain adequate dust collection with smaller fans and dust collectors. The result is dramatic energy savings for manufacturers adopting the Ecogate system. On average, manufactures converting to the Ecogate MASTER systems have realized electricity savings of 68%.
Nordfab has built a nationwide network of dust collection professionals to distribute Quick-Fit clamp-together ducting. This network has made Quick-Fit the premier clamp-together ducting in America, covers every conceivable industry and has ties to all major dust collection manufacturers. The Nordfab network, along with existing Ecogate dealers, will be the outlet for all Ecogate products.
"Ecogate, Inc. is proud to form a strategic partnership with Nordfab. Market acceptance of the Ecogate Systems has been very strong with more than 11,000 motorized gates and more than 1,100 systems installed," said Petr Litomisky, CEO of Ecogate, Inc. "Nordfab recognizes the value of this next-generation industrial ventilation system and can make Ecogate the norm for all cost-and-energy-conscious manufacturers."
"The future of manufacturing in North America hinges on producers being cost conscious and energy-efficient in every operation, including dust collection," said Niels Pedersen, Nordfab president. "We've reviewed the research and are convinced that by using Ecogate, manufacturers significantly reduce the size and energy costs of their dust collection systems. An added benefit is that many communities and electricity providers offer financial incentives to manufacturers investing in this type of technology."
Manufacturers can call 800-532-0830 to have a Nordfab/Ecogate dealer evaluate its dust system and provide an estimate energy savings and possible financial incentives an Ecogate system can provide. About DISA/ Nordfab Systems, Inc. Nordfab and DISA are part of the worldwide A.P. Moller Group, recognized throughout the world by its Maersk name. A.P. Moller Group has offices in 325 cities in more than 100 different countries, and employs some 50,000 people. The DISA Group employs 2,400 people world-wide, generating annual revenues of more than 300 million Euros.
Meeting with DISA representatives in Denmark, Europe.
About Ecogate, Inc.
ECOGATE®, Inc. was founded and incorporated in California in July 1997. In its first years the company developed a unique computer controlled System that enhances dust collection Systems to run more efficiently and save electricity costs. There is no comparable technology on the market and Ecogate, Inc. hold an exclusive System patent (U. S. Pat. 6,012,199). The Company shipped its first small System order (for home/commercial shops) in November 1999 and its first MASTER System (for industrial producers) in August 2000. To date, the Company has shipped orders totaling over 1,100 small systems and about 60 MASTER industrial Systems. About 11,000 energy saving motorized ECOGATE® gates are installed with these systems. In the year 2001, ECOGATE® won the prestigious Sequoia Award given by the Association of Woodworking & Furnishings Suppliers to organizations that demonstrate environmental innovation and leadership in energy conservation, in 2003 Energy Star Award. In the year 2003, ECOGATE® won AWFS 2003 Award for new Plant Monitoring, DataMining software and "29th Annual Energy Efficient Building Awards" (Karges Furniture installation).
March
New ECOGATE software wizards, version 1.95 (Build 03.19.04) are now available. Improvements includes easy to use "navigation bar", and many small improvements.
February
New Ecogate MASTER Installations. We are finished pilot installation for one of the largest U.S. woodworking manufacturers - Universal Forest Product (300 HP system for their California Riverside plant). Another finished installation of MASTER 75 HP system is for Merritt Woodwork in Ohio. Current projects: installation for Patrick Industries in Oregon (incentive, about 55% of project cost was approved approved by power company). Installation will finish in March. Sauder Woodworking in Michigan are installing they first ECOGATE MASTER system; they have totally 32 dust collecting systems 250 Hp in one location. Installation will be finished during the March.
February: Lion Capital Holdings Signs on Ecogate, Inc.
Lion Capital Signs Yet Another Funding Agreement - Leader in the Field of Industrial Ventilation
AUSTIN, TX - February 4, 2004: Lion Capital Holdings Inc. a investment banking and consulting firm today announced that it has signed a new funding agreement with Ecogate, Inc., a company with a proven record of exceptional energy savings in the field of industrial ventilation.
"We're very pleased to announce our new agreement with Ecogate," said Tim Page, CEO of Lion Capital. "We believe Ecogate differentiates itself as an industry leader in delivering home and industrial ventilation products. This is clearly demonstrated by the recent multi-million dollar sales agreement they have signed with a major US company."
"I am excited about the opportunity to take this company to the next level," commented Ales Litomisky, President of Ecogate. "Our focus from this point turns to financing the production increase based on our recent agreement signed for exclusive distribution rights in the US, and training our sales and technical resources." Ecogate executives said the new funding agreement with Lion Capital will help the Company grow to meet increasing demand for its products and services. The "Ecogate System" is patented technology offering a new and innovative application in the field of industrial ventilation, providing this underserved industry with energy savings of 40% to 80%. Additional benefits include reduced noise and dust levels in facilities. The firms did not disclose the level of funding provided.
About Lion Capital Holdings, Inc.
Lion Capital Holdings is a boutique investment banking and consulting firm, providing a unique funding alternative, through its Velocity Growth Program, to private micro-cap companies, by transitioning them to publicly traded status. As consultant and facilitator, Lion Capital offers a comprehensive suite of services and assists its clients with all aspects of corporate and SEC governance, business development, access to capital markets, corporate finance, equity lending, market development, and investor and shareholder relations. Further details are available on Lion's web site at http://www.lioncapitalholdings.com.
January
New Generation of Ecogate Systems are under development. Objective: radically reduce product cost & reduction of installation cost (to make return on investment much shorter), more user-friendly software user interface, better performance of dust collecting (higher savings at proper drop velocities). First available improvement will be possibility to setup and monitor greenBOX PRO system via any Windows PC with serial channel.