Sustainable heating modernization at 3A Composites: "CO2 emissions reduced by over 74 %."

"We quickly realized the great advantages of infrared heat in halls."

Nicknamed "Die Alu" by the people of Singen, Alusingenplatz 1 has a tradition dating back over 100 years as one of the first German production sites for aluminum foil. Today, 3A Composites shares the extensive site in southern Baden-Württemberg with two other international companies. From here, the global player's aluminum composite panels are shipped all over the world as huge ALUCOBOND® panels, some of which are 11 meters long.

In 2023, a new double hall in lightweight construction with an area of around 2,000 square meters and a ridge height of eight meters was built to store the primary material. Just a few months later, 3A Composites decided to also heat the existing 20 x 55-metre hall for central packaging.

The heating requirements

For many years, a central combined heat and power plant supplied the entire Alusingen site with steam for processes and heat. After the decision was made to phase out coal energy and dismantle the power plant, 3A Composites was faced with a new heating issue. The team headed by Donath Pochaba (Head of Engineering and Strategic Projects), which planned the heating of the two hall projects, had very clear ideas about the criteria that needed to be met:

"We have opted for what we consider to be the best system."

• High reliability and operational safety
• Homogeneous, pleasant heat distribution for employees
• Control of relative humidity (corrosion protection)
• Remote access and integration into existing energy management system
• Low-consumption operation (high energy efficiency)

The decision was made in favor of the highly efficient MAXIMA infrared heating line from KÜBLER. Also because a neighboring company had already had very good experience with this dark radiator technology and because the intelligent KÜBLER CELESTRA system was also able to meet all requirements in terms of control technology.

The technical solution

1. logistics hall 1 and 2 (lightweight construction)
In April 2023, eight gas-powered infrared heaters from the MAXIMA line were put into operation at a height of around seven meters in the new 55x35 meter double hall for storing the coils needed to produce the aluminium composite panels. The high-efficiency class from KÜBLER is considered to be the most efficient dark radiator technology with over 80 percent infrared efficiency. The systems supply the two hall areas reliably and evenly with heat at very low energy consumption, without causing air movement or raising dust. Retrofittable as a MAXIMA E-Hybrid system, the new heating system could in future be operated even more climate-friendly with electricity from wind and solar energy. An option that is not yet attractive due to high electricity prices.

"We have opted for what we consider to be the best system."

The two logistics halls are each divided into two heating zones and are heated at a target temperature of 12 °C. Automatic control is provided by the patented CELESTRA digital control system, which was specially developed for the optimum and energy-efficient operation of infrared hall heating systems. This KÜBLER control system is an important factor for ease of use and minimized energy consumption in the 3A Composites heating concept, as it automatically adjusts the heating mode in the individual heating zones to the ideal line. Changes can be made very easily and intuitively via the graphic control panel or on the PC. The self-explanatory "operating concept without operating instructions" is a unique feature of the smart, modular control system. The control system is supplemented by the WinTec extension modules for remote control and HygroTec for preventing condensation in moisture-sensitive stored goods. The EMMA energy management module is also in use at 3A Composites. It ensures real-time transparency across the entire heating process and provides the relevant analysis data for reporting, e.g. in accordance with DIN EN 50001.

2. central packaging (existing hall)
The hall building with the 56-metre-long, in-house developed packaging machine was previously heated by old air blowers. These were also replaced in June 2023. Since then, the heat supply for the central packaging at 3A Composites has also been provided by the economical MAXIMA systems. Three heaters were installed at a height of 7.50 meters, which are controlled in a heating zone by CELESTRA at a target temperature of 19 °C. The system is also designed for remote control and energy management. Changes to working shifts, weekend and vacation times can be easily adjusted via PC or directly on the color display of the digital control system.

" 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

The installations went according to plan in both projects and went into operation on time for the 2023/2024 heating period. 3A Composites is also very satisfied with the feeling of warmth in the halls. After initially missing the warm air, the employees find the even, draught-free heat much more pleasant after a short period of getting used to it, despite the lower temperature.

"The energy costs are even lower than initially calculated."

The expectations for the energy efficiency of the new heating systems were exceeded in both hall projects. In the double logistics hall, an annual consumption of 180,000 kWh was initially assumed. After the first heating period, the meter read 70,000 kWh - 61 percent less than planned. The savings actually achieved in the central packaging department were similarly high. Instead of around 500,000 kWh per year before the energy refurbishment, the new MAXIMA system only consumed 197,000 kWh. A welcome contribution to cost savings and to the sustainability goals of the Singen-based company, as greenhouse gas emissions have also been reduced accordingly. By switching to natural gas as a low-CO₂ energy source, emissions in the existing hall were even reduced by over 74%!

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."