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

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:

• 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 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."