Energy consulting for medium-sized companies at Brendle GmbH & Co. KG in Dettingen/Erms
Within the framework of the BAFA-sponsored 'Energy consulting for medium-sized enterprises' (EBM), the entire Brendle GmbH & Co. KG in Dettingen/Erms was analysed under the aspect of energy efficiency. In the run-up, relevant data was collected by the company's employees and completed during the on-site visit by the consultants from OPTENDA (until April 2020 GILDEMEISTER energy efficiency GmbH), so that a detailed energy-related starting point was determined. In addition to the purchased energy quantities and costs, the recorded data includes performance data, operating hours and years of construction of the individual plants and machines. Furthermore, the current load curve from 2016 was processed and analysed in detail. The subsequent analysis focused on heat and compressed air generation and hall lighting.
When checking for possible energy savings could in the individual areas amongst other things the following potentials are identified:
- Heat generation: By setting a night and weekend reduction and by replacing the heating pumps, the company could save around 4,800 kWh of oil and just under 500 kWh of electricity per year. In this context, reference was made to the use of the "Heating Optimization" funding program by the Federal Office of Economics and Export Control.
- Compressed air generation: The waste heat of the compressors is currently used only sporadically for the hall heating. This resulted in additional usable waste heat of around 80,000 kWh per year. In addition, the compressors are to be disconnected from the grid during production-free periods, resulting in an electrical energy saving of over 3,200 kWh per year. Reducing the operating pressure by half a bar achieves annual savings of around € 550.
- Lighting: T8 and T5 fluorescent tubes with different ballasts are currently installed in the production halls. Due to two- or three-shift operation and the associated high usage time, the payback period for a replacement for LED lighting is very low and is less than three years. This measure could save at least 17,000 kWh of electrical energy per year.
Within the scope of the consulting services, a ventilation and air conditioning concept for the production halls was also drawn up for Brendle GmbH & Co. KG. Among other things, the waste heat of the air compressors can be used for this purpose via an adsorption system for the provision of cooling.
During the on-site inspection two energy meters were installed. The measuring devices record the electricity supply from the distribution network and the generation of the PV system. Thanks to the monitoring system, a regular recurrent load peak could be identified on the weekends. Closer examination of the reason for this was identified in the non-disconnected air compressors. Corresponding corrective measures could be initiated purposefully. In general, energy monitoring makes sense, as it allows valid and up-to-date energy data to be used. Optimization measures can be calculated much better by the monitoring and can be tracked after implementation.
Thanks to the energy consulting, several possibilities for energy savings were presented to Brendle GmbH & Co. KG and quantified with concrete calculations. The measures described can now be implemented step by step.
As a specialist in the field of precision turned and precision milled parts, Brendle GmbH & Co. KG supplies its customers with prototypes, special series and serial parts. In addition to mechanical and automotive engineering, the sectors supplied include the electrical industry as well as process engineering and medical companies. An example product of the company Brendle GmbH & Co. KG are the nozzles for sewer and ultra-high pressure cleaning.
OPTENDA, formerly GILDEMEISTER energy efficiency GmbH, headquartered in Stuttgart, offers its customers holistic and individual solutions in the areas of energy monitoring, energy management, optimization of the energy efficiency of buildings, technical systems and processes as well as the reduction of energy costs.
Quotation on the EBM of Hr. Andreas Brendle; managing Director
“Very competent and friendly advice. Many hints and tips, which lead to significant savings when consistently implemented.”