How the Ecogate System Works

Sequence of Operation

Sensor is triggered before operator starts cutting

Gate processor transmits sensor info to greenBOX

greenBOX opens & closes gates, calculates fan speed

VFD starts/stops fan, adjusting its speed based on demand

Any dust collectors error automatically stops the fan

How Ecogate Improves Ventilation Systems

1. Initial Setup

When a ventilation system is first installed, the main duct and all workstations get the right amount of airflow.

The fan runs at full speed to support all workstations, even when demand is low.

100 = Minimum Conveying Velocities

100 = Drop Air Velocities

How Substantial Savings are Possible

Leveraging the Fan Law

Fan power doesn’t decrease at the same rate as airflow—it follows the Affinity Laws, meaning small reductions in air volume lead to exponentially larger energy savings. For example, cutting airflow by just 30% reduces fan power demand by nearly 70%, as shown in the graph. This is because fan energy consumption is proportional to the cube of airflow reduction.

10% reduction in airflow → ~27% energy savings
25% reduction in airflow → ~68% energy savings
50% reduction in airflow → ~87.5% energy savings

How Common are the Savings?

Average Workstation Utilization

Managers often assume machines operate continuously, estimating utilization at 80% or more based on busy production floors. But data from hundreds of Ecogate installations, mostly U.S. woodworking facilities, reveals actual utilization averages around just 50%.

Machines don’t need ventilation during loading/unloading, setup, programming, cleaning, maintenance, or idle periods. Recognizing this difference between a machine being on and a machine needing ventilation uncovers substantial energy savings potential.