Readings on the Ecogate® greenBOX MASTER SRL controller showed energy savings of 62% from day one.  

Machine activity is constantly monitored with the controller continually optimising the amount of power supplied to the fans via the variable speed drive.  
Motorised gates are fitted to 19 woodworking machines. By closing gates to machines not in use, fan speed is reduced and efficient extraction is maintained for other machines.  


Alan Nuttall Ltd, one of the UK's leading retail shop fit-out specialists, has recently commissioned Dust Control Systems to install Ecogate technology to reduce dust extraction operating costs at its manufacturing site in Dudley, West Midlands.

The privately owned company employs over 500 people across three Midlands-based factories from where it designs, manufactures and installs a vast array of display equipment, furniture and signage for the retail, catering, leisure and commercial sectors.

The Dudley facility is home to the company's Store Fitting division which manages projects from initial concept stage through to large multi-site roll-outs. All display equipment is designed and produced on site, with manufacturing being carried out in either their metal or joinery workshops.

The joinery workshop is equipped with high-performance machines including CNC routers, edgebanders, a planer moulder, panel beam saw, sliding table panel saw and a wide belt sander. Classical machines include a ripsaw, bandsaw, crosscut, thicknesser and three spindle moulders. Woodwaste is dealt with by a powerful, DCS supplied, filter plant which utilises two extraction fans and a conveying fan.

Following an initial energy survey, which provided an assessment of the extraction demand from each woodworking machine, DCS identified significant opportunities for energy savings. Chris Oldfield of DCS explains: "Extraction of dust waste was originally set up to run at full load for all the shift hours – regardless of the number of woodworking machines in use. By efficiently adjusting the speed of the fans, to meet actual workload, we were confident that major energy savings could be achieved."

At Nuttall's, DCS has achieved savings of around 60% by installing an Ecogate® greenBOX MASTER SRL controller, together with individual motorised gates to 19 woodworking machines. The MASTER SRL unit controls all motorised gates, receives signals about machine activity, controls the variable speed drives and continually optimises the amount of power supplied to the fans. By closing gates to machines not in use, fan speed is reduced whilst still efficiently extracting wood dust in other areas of the workshop. The system is programmed to open selected gates to maintain proper airflow through the ductwork.

The controller has a heavy-duty touch screen monitor with dust and waterproof keyboard. It displays 'real time' statistics including motorised gate status, negative pressure readings, electricity savings (current & average) and kW levels for each fan. The system can also be monitored and managed via remote internet access and includes functions to modify individual fan speeds and variable speed drive programming. System monitoring and evaluation of energy savings is managed using Windows-based software.

Bob Williams, works manager at the Dudley site says: "We are constantly looking for energy saving opportunities throughout the factory and retrofitting the Ecogate energy-saving system makes sound business sense. Everyone is impressed with the Ecogate System which provides us with 'on demand' extraction without wasting valuable energy. We can see exactly what we're saving on screen and, right from day one, readings were showing savings of 62%."


Dust Control Systems Ltd., Horace Waller VC Parade, Shawcross Business Park, Dewsbury, WF12 7RF
Telephone: +44 (0)1924 482500   E-mail:
Freephone: 0800 0407116

Sitemap Terms & Conditions