Sense production demand
Activity sensors detect when a machine or collection point requires ventilation, so the system responds to real production demand.
Explore Workstation Activity Sensors →top of page
Everything You Need to Make Industrial Ventilation Demand-Based
Ecogate brings engineering, automated airflow control, variable-speed fan regulation, analytics, commissioning, and ongoing support together in one coordinated system for industrial dust, fume, and mist collection.
Instead of ventilating every workstation as if it were operating at once, Ecogate directs airflow where work is happening, adjusts fan speed to match demand, and helps maintain the airflow your system requires.
Demand control active
Closed-loop response
WorkstationsDemand detected
Smart GatesAirflow directed
the greenBOX
System demand calculated
Power MasterFan speed regulated
AnalyticsPerformance documented
Airflow feedbackResult verified
Active stations03 / 12
Fan demand62%
Airflow statusVerified
Control modeAutomatic
66% SavingsAverage reduction in dust collection fan electricity use
1–3 YearsTypical return on investment, often under two years
25+ YearsOf proven on-demand industrial ventilation installations
40,000+Automatic gates sold globally
50–70%Common utility-incentive coverage for qualified projects
Savings and payback vary with fan horsepower, operating hours, system utilization, electricity rates, duct conditions, and project configuration. Utility incentives vary by location, eligibility, and program and are not guaranteed.
Ecogate System Sequence of Operation
Sensors, gates, the greenBOX controller, fan-speed regulation, measurement, and reporting operate as one coordinated system. Each layer receives or confirms the same demand signal as production changes.
Direct airflow where it is needed
The corresponding automatic gate opens to direct airflow to the active workstation. Smart and Precision Airflow Gates can also report pressure, velocity, and volume.
Explore Ecogate Smart Gates →Calculate and protect total airflow
The greenBOX combines demand across the duct system, calculates the required fan airflow, and protects the configured minimum transport velocity.
Explore the greenBOX →
Match fan speed to demand
Power Master follows the airflow command from the greenBOX and regulates fan speed as the combination of active workstations changes.
Explore Power Master VFD →
Measure, document, and improve
System measurements and Ecogate Analytics make airflow, pressure, fan power, savings, utilization, and performance visible.
Explore Ecogate Analytics →Ecogate Hardware for Demand-Based Intelligent Ventilation
Explore the complete Ecogate ecosystem, from controllers and automatic gates to sensing, collector intelligence, installation hardware, and cabling. Select any component for a concise explanation, availability details, and a product link where available.
System controllers
Coordinate the control loopthe greenBOX Nxt
the greenBOX Max
the greenBOX Master
the greenBOX Pro
the greenBOX 12
Collector intelligence and system integration
Monitor, configure, regulate
Dust Collector Interface
Dust Collector Controller
Netbook
Power Master VFD
Gates and installation hardware
Direct and control airflow
Rotating Blade Bodies
Butterfly Gate Bodies
Smart Gate Actuator
Precision Airflow Actuator
Standalone Actuator
Standard Gate Actuator
Gate Tester
Steel Flanges
Flange-to-QF Adapters
Sensors, measurement, and operator inputs
Detect, verify, signal
AC/DC Volt Sensor
AC Volt Sensor
Current Sensor
Pressure Tap
Auto Shut-Off Timer
Averaging Air Velocity Sensor
Proximity Sensor
Remote Button
Vibration Sensor
Cabling and system status
Connect and communicate
Master Cable
Sensor Cable
Standard Cable
Status Traffic Light
Together, these components detect workstation demand, direct airflow, calculate system requirements, regulate fan speed, monitor collector conditions, verify performance, and connect the installation into one coordinated Ecogate system.
Your One-Stop Shop for Demand-Based Industrial Ventilation
Ecogate connects the technology, engineering, commissioning, and long-term support required to turn the control strategy into a working system.
Audit, assess, and measure
Conduct on-site energy audits across dust, mist, and fume systems. Evaluate airflow, pressure losses, fan power, system capacity, workstation demand, operating schedules, and existing equipment. Utility-recognized measurements can also support financial-incentive applications.
Engineer the system
Define duct zones, airflow requirements, gates, sensing, controller capacity, fan regulation, and the project business case.
Supply and integrate
Provide the control hardware and software, then coordinate with local mechanical and electrical contractors as needed.
Commission and verify
Calibrate airflow, configure duct zones, validate fan control, test sequences and alarms, and train operators.
Monitor and support
Use Analytics, remote monitoring, technical support, training, and service plans to support long-term performance.
One coordinated path from airflow study to measurable performance
Ecogate is more than a component supplier. Depending on project scope, our team can assess the system, engineer the demand-based strategy, supply the controls, coordinate integration, commission and calibrate the system, and support performance after startup.
- Energy audits, engineering analysis, and project documentation
- Hardware, software, and system integration
- Commissioning, calibration, and training
- Analytics, monitoring, and ongoing support
Designed Around Your Facility
Ecogate can be applied to new systems, existing systems, and facilities that need to expand or reconfigure production.
Retrofit an existing system
Many existing dust, fume, and mist collection systems can be converted to demand-based operation. An engineering review considers the collector, fan, motor, duct design, air velocities, pressure losses, system condition, workstations, and production schedule before determining the appropriate control strategy.
Design a new system
By evaluating realistic peak concurrent demand, Ecogate engineering can help right-size airflow, ductwork, collector capacity, fan power, and controls for the way the facility is expected to operate.
Expand or reconfigure production
Ecogate systems can be updated as workstations move, equipment is added, and production requirements change. Engineering review and recalibration help keep the control strategy aligned with the revised operation.
Results Built on Engineering, Measurement, and Real Facilities
The value of demand-based ventilation should be demonstrated through engineering analysis and operating data, not unsupported promises.
Metrie
1.6 million kWh
Metrie projects approximately 1.6 million kWh in annual electricity savings. Puget Sound Energy provided incentive support covering 70% of the total system cost, including ductwork replacement.
Read the Metrie success storyNova Labs
$1M to $150K
With Ecogate engineering support, a right-sized duct design, an Ecogate control system, and a community-led self-installation model, Nova Labs completed a project for approximately $150,000 after turnkey alternatives approached $1 million.
Read the Nova Labs case studyEcogate has thousands of installations across woodworking, aerospace, automotive, pharmaceutical, laboratory, metalworking, food processing, education, government, and cleantech environments.
25+Years of experience
40,000+Automatic gates sold
GlobalIndustrial installations
See What Happens After Startup
A commissioned system should not become a black box. The greenBOX and Ecogate Analytics can show how the system operates, where energy is being used, and how production demand changes over time.
- Fan electricity use
- Documented savings
- Air volume and velocity
- Fan and filter pressure
- System utilization
- Workstation utilization
- Device health and alarms
- Historical reports and CSV exports
Questions About the Ecogate System
The most common questions facilities ask before moving from fixed ventilation to demand-based control.
Often, yes. An engineering review evaluates the fan, motor, collector, duct design, air velocities, pressure losses, workstations, operating schedule, and system condition before Ecogate recommends a control strategy.
No. A VFD can change fan speed, but it does not know which workstations are active, how much airflow the duct system requires, or whether minimum transport velocity is being maintained. Ecogate combines sensing, gates, the greenBOX, fan regulation, airflow measurement, collector monitoring, analytics, engineering, commissioning, and support.
The greenBOX calculates required air volume across the duct system and uses airflow measurements as closed-loop feedback. If additional airflow is needed, the system can open selected gates in inactive areas. A properly designed, installed, and calibrated Ecogate system is designed to maintain required airflow and fulfill the relevant control-system requirement when gates or dampers are used. The control system alone does not guarantee complete facility compliance.
The delivery model depends on project size, customer capability, location, and scope. Ecogate can manage control-system installation projects and coordinate with local contractors. Authorized dealers can support installation, and smaller systems may be customer-installed with Ecogate documentation and training.
Projections can consider fan horsepower, measured fan power, operating hours, workstation utilization, required airflow, duct conditions, electricity rates, and the proposed control strategy. The savings calculator provides an initial estimate, while engineering analysis provides a more project-specific projection.
Yes. Depending on installed equipment and service plan, the greenBOX and Ecogate Analytics can track fan power, utilization, airflow, pressure, and electricity savings. Historical reports and downloadable data can make results available for customer or utility review.
Ecogate systems can be updated as production changes. New or relocated workstations may require revised sensing, gate configuration, airflow requirements, duct-zone settings, and recalibration. Ecogate support can help review and implement those changes.
Many North American utilities offer custom incentives for projects that reduce electrical demand and annual energy use. Ecogate has experience supporting applications with engineering analysis and savings calculations. Availability, eligibility, and incentive value vary, and incentives are not guaranteed.
Start With the System You Have
You do not need to arrive with a finished specification. Tell us about your collector, fan horsepower, workstations, operating schedule, facility changes, and current challenges.
An Ecogate engineer can help determine whether demand-based control is a good fit and where the strongest operational and financial opportunities may exist.
Phone: +1 (818) 506-6016
Email: info@ecogate.com
Complete Ecogate system component directory
the greenBOX Nxt
Coordinates demand-based ventilation for facilities with up to 75 gates and provides a built-in touchscreen interface.
View the greenBOX Nxtthe greenBOX Max
Controls large multi-system facilities with up to 150 gates, a 15.6-inch display, and redundant power.
View the greenBOX Maxthe greenBOX Master
Provides maximum control capacity for very large facilities with up to 225 gates and multiple ventilation systems.
View the greenBOX Masterthe greenBOX Pro
Brings the current Smart System platform to smaller facilities with up to 36 gates.
View the greenBOX Prothe greenBOX 12
Automates smaller Standard Gate systems with up to 12 workstation channels and basic fan-speed control.
View the greenBOX 12Dust Collector Interface
Brings collector pressure, airflow, alarms, and operating status into the greenBOX dashboard.
View Dust Collector InterfaceDust Collector Controller
Adds coordinated VFD control and monitoring for dust collector motors and auxiliary equipment.
View Dust Collector ControllerNetbook for the greenBOX 12
Provides the Windows setup and monitoring environment used to configure and support the greenBOX 12.
View Netbook for the greenBOX 12Power Master VFD
Matches dust collector fan speed to the airflow demand calculated by the greenBOX.
View Power Master VFDRotating blade gate bodies
Heavy-duty gate bodies suited to demanding dust loads and larger conveyed particles.
View Rotating blade gate bodiesButterfly-style gate bodies
Sealed gate bodies for flexible installation in fume, mist, laboratory, and lower-particulate applications.
Available upon request. Contact Ecogate for availability and project fit.
Smart Gate Actuator
Adds Modbus communication, position confirmation, and pressure, velocity, and air-volume measurement.
View Smart Gate ActuatorPrecision Airflow Gate Actuator
Combines Smart Actuator feedback with proportional blade positioning in one-percent increments.
Available upon request. Contact Ecogate for availability and project fit.
Standalone Gate Actuator
Opens and closes from a local activity sensor without requiring a greenBOX controller.
View Standalone Gate ActuatorStandard Gate Actuator
Provides open-and-close automation with limit-switch confirmation for the greenBOX 12.
View Standard Gate ActuatorGate Installation Tester
Measures actuator current so installers can verify that a gate is supported and operating correctly.
View Gate Installation TesterSteel flange rings
Industry-standard flange-ring pairs connect Ecogate gates to traditional flanged duct systems.
View Steel flange ringsFlange-to-QF adapters
Connect Ecogate angle-flange gates to clamp-together Quick-Fit duct systems.
Available upon request. Contact Ecogate for availability and project fit.
AC/DC Volt Sensor
Detects activity from 24 to 230 volts AC or DC and signals the corresponding Ecogate gate.
View AC/DC Volt SensorAC Volt Sensor
Detects workstation activity from higher-voltage AC circuits ranging from 110 to 690 volts.
View AC Volt SensorHawkeye Current Sensor
Detects workstation activity by measuring AC current around a single phase conductor without a direct electrical connection.
View Hawkeye Current SensorEcogate Pressure Tap
Provides an AMCA-style static-pressure measurement point for industrial ventilation ductwork.
View Ecogate Pressure TapAuto Shut-Off Timer
Provides a timed ventilation request for cleanup, welding, or workstations without an electrical activity signal.
View Auto Shut-Off TimerAveraging Air Velocity Sensor
Measures airflow across the clean-side duct cross-section for accurate real-time velocity feedback.
View Averaging Air Velocity SensorProximity Sensor
Detects material presence or operator activity where a machine-voltage signal is not the best trigger.
Available upon request. Contact Ecogate for availability and project fit.
Remote Button
Allows an operator to request or stop ventilation locally for a workstation, arm, or process.
Available upon request. Contact Ecogate for availability and project fit.
Vibration Sensor
Monitors fan and motor vibration to help identify mechanical wear before a failure occurs.
Available upon request. Contact Ecogate for availability and project fit.
Ecogate Master Cable
Carries 24-volt power and Modbus communication between the greenBOX, Smart Gates, and Power Master VFDs.
View Ecogate Master CableEcogate Sensor Cable
Connects workstation volt and current sensors to Standard or Smart Gate signal inputs.
View Ecogate Sensor CableEcogate Standard Cable
Connects the greenBOX 12 to individually wired Standard Gate actuators.
View Ecogate Standard CableStatus LED Traffic Light
Provides an at-a-glance green, amber, or red indication of system status and can include an audible alert.
Available upon request. Contact Ecogate for availability and project fit.
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