Sustainable heating modernization at 3A Composites: "CO2 emissions reduced by over 74 %."
July 10, 2025
3A Composites is setting new standards in sustainability with innovative heating technologies.
3A Composites, a leading manufacturer of plastic sheets, aluminum composites and lightweight materials, is setting new standards in terms of sustainability with innovative heating solutions. As part of Schweiter Technologies AG, the long-established Singen site sets the highest environmental standards. In 2023, two heating projects were on the agenda there: the new lightweight hall for coil storage and the modernization of the existing packaging hall. The focus: energy efficiency, thermal comfort and durability.
The "Die Alu" site looks back on over a century of aluminum history. Today, 3A Composites and two other companies produce on the site in the south of Baden-Württemberg. A new lightweight hall with an area of 2,000 m² was built in 2023 to store the primary material. Shortly afterwards, the 20 x 55 m packaging hall was also modernized in terms of energy efficiency.
The heating requirements
After the phase-out of coal, the heat supply had to be restructured. The project team, led by Donath Pochaba (Head of Engineering and Strategic Projects), defined clear requirements:
"We have opted for what we consider to be the best system."
- High operational reliability
- Uniform thermal comfort
- Humidity regulation for corrosion protection
- Remote access and integration into energy management
- Efficient, economical operation
The choice fell on the infrared heating line MAXIMA from KÜBLERsupported by the control system CELESTRA - tested and precisely customizable.
The technical solution
1. logistics hall 1 and 2 (lightweight construction)
In April 2023, eight MAXIMA gas-powered infrared radiant heaters were installed at a height of seven meters for the 55 x 35 m hall. With an efficiency of over 80 %, they are among the most efficient dark radiators on the market. They provide uniform heat without air turbulence - with minimal energy consumption. A hybrid conversion with green electricity is planned, but is not yet practical.
The hall is divided into two heating zones and is operated at 12 °C. CELESTRA controls operation automatically and efficiently - with intuitive operation via touch panel or PC. The system is supplemented by WinTec (remote access), HygroTec (condensate protection) and EMMA (energy management in accordance with DIN EN 50001).
2. central packaging (existing hall)
The 56-metre-long hall with the large packaging system was converted to infrared technology in June 2023. Three MAXIMA devices supply the hall at a target temperature of 19 °C, controlled by CELESTRA. Shift schedules, weekend operation or vacation times can be flexibly controlled - via color display or PC.
" The consultation, the installation, the coordination - everything went smoothly. Everyone knew what they were doing." Donath Pochaba, Head of Engineering and Strategic Projects
The results
Both systems went into operation in time for the 2023/2024 heating season. Unusual at first, the draught-free radiant heat is now perceived as much more pleasant by employees.
The systems were also impressive in terms of energy efficiency:
- In the logistics hall, consumption fell from a planned 180,000 kWh to just 70,000 kWh p.a. 61 % Savings.
- Instead of 500,000 kWh per year, only 197,000 kWh were consumed in the packaging hall.
CO₂ emissions were reduced by switching to the energy-efficient MAXIMA infrared technology by over 74 % - a clear success for the company's climate targets.
The bottom line
"With these results, you can only be satisfied, right? All our expectations have been met and even exceeded," says Donath Pochaba. "The energy costs are even lower than calculated. This is very beneficial for us, especially in the current situation with high energy prices."
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