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The 23% Rule: How Ecogate Safely Reduces Air Volume Without Dropping Below Minimum Transport Velocity

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What's in this paper

  • The 23% Rule — how far you can close gates before velocity drops too low

  • Fan Affinity Law math — why 77% air volume = 47% fan power

  • Real factory data — measured duct velocities across 137 US facilities

  • How greenBOX enforces minimum transport velocity across every branch

  • Duct sizing guidance for new Ecogate system designs

Most engineers assume you can't slow down a dust collection fan without risking dangerous dust fallout in the ductwork. This whitepaper, written by Ales Litomisky, Ecogate's Co-Founder and Chief Engineer, explains why that assumption is wrong — and how Ecogate on-demand systems exploit the gap between design velocity and minimum transport velocity to deliver real energy savings.

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The key insight is deceptively simple: a duct designed for 4,500 FPM doesn't need to run at 4,500 FPM when only half the workstations are active. Ecogate's greenBOX intelligently manages gate positions to maintain safe minimum transport velocity — typically 3,500 FPM — while the fan runs at just 77% of its design air volume. Per the Fan Affinity Laws, that 23% reduction in air volume reduces fan power consumption to 47% of full load — a 53% electricity savings.

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Inside, you'll find the full engineering explanation: fan curve mechanics, the two pressure-compensation mechanisms that make this work, real duct velocity data from 137 US woodworking factories, and how NFPA 660 compliance is maintained throughout.

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