Ecogate recently completed the installation of a greenBOX Master system at the Renewal by Andersen factory in Cottage Grove, MN. The factory in Cottage Grove, MN was recently expanded by 125,000 square feet, adding approximately 200 jobs.
Many new machines were added in the expansion. A new dust collection system was put in place to supply all of the machines with good dust extraction.
Since its founding as Andersen Lumber Company in 1903, Andersen Corporation has been relentlessly focused on technological innovation to deliver outstanding quality windows and doors. Today, Andersen Corporation employs more than 11,000 people. Renewal by Andersen, which focuses on replacement windows and doors for existing buildings, was founded as a subsidiary in 1995. The Renewal by Andersen factory in Cottage Grove, MN was recently expanded by 125,000 square feet, adding approximately 200 jobs.
Many new machines were added in the expansion. A new dust collection system was put in place to supply all of the machines with good dust extraction. To design the new system, Mark Dupre, Technical Leader I at Andersen Corporation, worked together with Ecogate. Andersen has a strong corporate sustainability program, and the company works to "continuously uncover new ways to reduce our overall environmental footprint, while maximizing our positive impacts across the triple bottom line of people, planet and profit." Ecogate, as the maker of the world's most advanced and energy-efficient dust collection control system, is a perfect provider.
The new dust collection system is serviced by a single 400 HP fan. Each machine is equipped with an Automatic Ecogate Blast Gate, which opens to provide dust collection when necessary, and closes when the machine is not in use. A Power Master Variable Frequency Drive modulates the fan motor speed to match the system air volume to the requirements of all the machines in real-time. The system always maintains transport velocities, and also starts and stops automatically. The system in Cottage Grove was commissioned in January 2016.
Compared to a traditional system of the same capacity, the Ecogate-controlled system at Renewal by Andersen used less than half the electricity. This is due to the Fan Law, which explains that the fan power varies with the cube of the air volume. As a result, even a modest reduction in air volume leads to substantial electricity savings.
In the first 6 months of 2016, Ecogate reduced the facility's electricity use by over 700,000 kWh, which is equivalent to reducing its carbon footprint by 1,100,000 lbs. CO2. "Overall, I'm very impressed with Ecogate," says Mark Dupre. The whole system is controlled by Ecogate's state-of-the-art greenBOX MASTER controller. Beyond its outstanding reliability, energy-efficiency, and ease of use, the greenBOX MASTER also provides Renewal by Andersen personnel with secure remote access.
This comes in handy, Mark says: "Being able to check on the system remotely has saved me several weekend trips to the factory."
Once per month, the system emails a summary of activity on the system for that month. This includes both details of the system's power use, utilization for each individual workstation, and more.
"The monthly summary emails are a tremendous leap forward in value of the information," says Mark Dupre. I like that I can easily disseminate and forward the information along."
Being able to check on the system remotely has saved me several weekend trips to the factory. - Mark Dupre - Technical Leader I, Andersen Corporation
At the current rate, Ecogate is projected to lead to annual electricity savings in excess of 1,300,000 kWh, while providing superior dust collection and other benefits. This is a great step for the bottom line as well as for the environmental footprint of the factory.
"I am glad we did the project," Mark concludes, "and look forward to doing more."