Energy consulting in medium-sized businesses conducted by Gutekunst GmbH - Metallverarbeitung
IAs part of the BAFA-sponsored 'Energieberatung im Mittelstand' (EBM), the entire site of Gutekunst GmbH - Metallverarbeitung in Römerstein-Zainingen was analyzed from the point of view of energy efficiency. In advance, relevant data was collected by the company's employees and completed by the consultants of OPTENDA (until April 2020 GILDEMEISTER energy efficiency GmbH) during the on-site visit, so that a detailed energetic starting point was determined. In addition to the quantities and costs of energy purchased, the data collected includes performance data, operating hours and years of construction of the individual systems and machines. In addition, the electricity load from 2016 was prepared in detail and analyzed. The focus of the subsequent analysis was on compressed air generation, oil pumps, oil preparation and hall lighting.
When checking for possible energy savings could in the individual areas amongst other things the following potentials are identified:
- Compressed air generation: By a temporary measurement of the compressors over a period of seven weeks it could be determined that the compressed air generators are not switched off in production-free times. Since the compressed air network is extensive and has numerous leaks, the compressors are often at night and on weekends in operation. Switching off the compressors in production-free times could save around € 1,000 in electricity costs per year. The waste heat of the compressors is currently not used specifically. If it were to be used, approx. 53,000 kWh of heating oil could be saved.
- Lighting: T8 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 42,000 kWh of electrical energy per year.
As part of the consultation, a ventilation and air conditioning concept for the production halls was also created for Gutekunst GmbH. For this purpose, among other things, the waste heat of the air compressors and the lathes and milling machines can be used via an adsorption for the provision of refrigeration.
During the on-site inspection four energy meters were installed. The measuring devices record the electricity purchased from the distribution network, the electricity purchased from the plants in Hall 2, and the electricity purchased from the compressors. By measuring a relatively high base load could be shown. Reasons for this include the non-disconnected compressors and production facilities, which are in stand-by mode. Through a consistent shutdown of the systems, the base load and thus the power consumption can be reduced.
Through energy consulting, Gutekunst GmbH was able to present several options for energy savings and to quantify them with concrete calculations. The measures described can now be implemented step by step.
As a deep drilling specialist, Gutekunst GmbH - Metallverarbeitung is today a competent partner for more than 1,000 renowned customers from the machine tool industry, mechanical and plant engineering, the chemical industry and mold making. With a highly qualified and motivated team, workpieces are processed quickly, precisely and on favorable terms. The customers particularly appreciate the company's experience with complex workpieces made of high-quality, difficult-to-process materials.
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. Paul Junkermann; managing Director
“Without the expert advice from OPTENDA, we would have needed much longer to quantify the existing energy efficiency potential. Thanks to the project, we now know very well what we will do.”