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New hall heating - zero investment

December 1, 2019

KÜBLER offers an investment-free rental model for heating halls with its heating plant

  • Ecological due to significant reduction in CO2 emissions
  • KÜBLER already meets the CO2 targets for 2030 (Federal Climate Protection Plan)
  • Economical due to significant reduction in heating costs
  • No investment costs and depreciation in new heating systems
  • No costs for personnel and maintenance
  • Save 62 % of primary energy and 457 tons of CO2 p.a. with state-of-the-art infrared heating technology and make a profit of EUR 45,000 (HeizWerk project by Dexion, Laubach)

Ludwigshafen. Tens of thousands of the approximately 420,000 industrial and large halls in Germany are equipped with technically outdated heating systems that unnecessarily pollute the environment with many hundreds of thousands of tons of CO2. Energy-efficient refurbishment of these halls would also generate potential cost savings in the three-digit million range. The reason: many companies shy away from the investment costs and depreciation as long as the old heating system is still doing its job. But this need not be the case. The new, ecologically and economically innovative HeizWerk product from KÜBLER GmbH Ludwigshafen for heating industrial and large halls shows how industry can not only save many tons of CO2 without investment costs, but also generate profits at the same time. The company, which has been awarded the German Sustainability Award, among others, equips the halls with the latest and most efficient KÜBLER infrared heating technology - a key technology without which the climate protection targets in halls would be difficult to achieve and which today already achieves the CO2 reductions set for 2030 in the German government's climate protection plan. The fixed rental price also includes operational and maintenance management. Companies not only save on investment costs for new heating systems and ancillary costs such as personnel and maintenance; thanks to sustainable infrared key technology, HeizWerk costs are generally even lower than the total annual costs of the previous old heating systems. One of the first HeizWerk projects, an 8,500 m² hall complex, shows a total saving of 61.9 % of primary energy after 12 months, which corresponds to a reduction of 457.5 tons of CO2. After deducting the HeizWerk annual bill, the hall operator was left with a profit of EUR 45,000 in the P&L.

HEIZWERK SOLVES THE INVESTMENT BACKLOG FOR HALL HEATING SYSTEMS

Replacing outdated, inefficient heating systems in industrial and other halls was previously only possible by purchasing a new system, which entailed high investments. "It is understandable that companies focus their investment programmes primarily on optimizing production and processes, rather than on state-of-the-art heating systems in their production halls," says Thomas Kübler, founder and CEO of KÜBLER HeizWerk GmbH in Ludwigshafen. "In addition, larger investments with depreciation periods do not fit into the financial planning of many companies, especially when the economy is slowing down." And the CO2 reductions that are urgently needed in terms of climate policy are no longer the primary focus. Thomas Kübler: "Over a fifth of CO2 emissions in Germany are generated in the industrial/commercial sector, and we can no longer play down this fact. Energy efficiency has always been part of KÜBLER's DNA, and we are now expanding this with a new dimension of cost efficiency in our HeizWerk product." Thomas Kübler and his team of engineers have worked intensively on this task and redefined ecology and economy for heating systems in industrial and other hall buildings. Thomas Kübler: "In our experience, HeizWerk is the simplest, most economical and most climate-friendly system solution for reducing the investment backlog in the energy-efficient refurbishment of large-capacity heating systems in halls that are still fired by inefficient old systems with high CO2 emissions."

HEIZWERK PROVES: YOU CAN EVEN SAVE MONEY WITH KÜBLER CLIMATE PROTECTION

HeizWerk is a new service offering with a "360 degree carefree package". It includes all services from the analysis of hall-specific energy flows, planning, engineering and the installation of state-of-the-art, energy-saving KÜBLER infrared key technology to complete operational management. The companies have no investments, no depreciation, no operating expenses - they only pay for the energy consumption and the agreed system rental. The bottom line is this: Operators save significant sums of money per year, as the first model plants are now proving. And: They have a long-term ecological high-tech product, because the KÜBLER infrared heaters already fall below the CO2 reductions of 55 % (1990: 100 %) envisaged for 2030 in the German government's climate protection plan, which of course also has a positive effect on the upcoming CO2 price of initially 10 euros/t of emissions*.

COMPANY DEXION: "HEATING PLANT A COMPLETE SUCCESS!"

Dexion is the world's leading specialist for warehouse logistics solutions, based in Laubach, Hesse, and was one of the first companies to choose HeizWerk from KÜBLER. The opportunity to use an energy-efficient, environmentally friendly and cost-saving infrared heating system without having to invest and depreciate it was the deciding factor for Dexion to implement the refurbishment measure immediately. After more than a year of operation, Hans Fuhrmann, Director of Production, draws an extremely positive conclusion: "HeizWerk is a complete success for us. The results of the first year of operation have exceeded all expectations. Together with KÜBLER experts, however, we are already working on further efficiency optimizations." The heat consumption in the Dexion steel production hall has been reduced by 57 %, while the electricity consumption of the heating-related components has been reduced by almost 96 %. In total, almost 62 % of primary energy was saved, which corresponds to a reduction of 457.5 tons of CO2. But the result is not only impressive on the ecological side: after deducting the costs for the heat requirement and the rent for operating the system, the P&L showed a profit of EUR 45,000. "For us, HeizWerk is the pragmatic and economical answer to the alternative of renewing our previous hall heating system at investment cost," concludes Hans Fuhrmann. HeizWerk was thus also able to fulfill another of KÜBLER's forecasts: The annual costs for rent and system operation are below the total costs of the old heating system.

THE "360 DEGREE CAREFREE PACKAGE" FROM HEIZWERK FOR DEXION

KÜBLER bundled its highly efficient infrared systems for large-capacity halls, the complete digitalization of the heating process (WÄRME 4.0) and its expertise in engineering and digital system operation into a "360 degree carefree service package". Infrared heaters from the KÜBLER OPTIMA plus high-performance line were installed at Dexion. They ensure a comfortable and clean working environment in the 8,500 m² steel production hall. The infrared heat transfer does not heat the air in the hall, but primarily the room air and all objects are heated moderately to 20 °C. This is extremely effective, fast and clean. This is extremely effective, fast and can also be easily controlled in terms of time and space. This heat transfer does not produce any warm air that could cause draughts or dust turbulence. This is also the decisive advantage for the efficiency of infrared heat in high hall spaces. This is because no warm air cushion is formed by the heated and therefore lighter air, which could flow under the hall roof and largely fizzle out unused. KÜBLER makes consistent use of physical and digital possibilities for the benefit of the operator. Auxiliary energies such as those previously used for pumps and fans are almost completely eliminated. Thanks to this efficiency advantage, a total of almost 62 % primary energy savings could be realized at Dexion.

INTELLIGENT, DIGITALIZED CONTROL TECHNOLOGY MAKES FURTHER SAVINGS POTENTIAL AVAILABLE

The monitoring, i.e. the permanent supervision of the new heating system, is carried out by KÜBLER - via the online energy and heat management system E.M.M.A. This name stands for Energy Monitoring & Management Application. The powerful online control system also provides the consumption analyses and documentation that Dexion needs for internal quality management and for audits in accordance with ISO 50001 and ISO 14001. The transparency provided by the E.M.M.A. energy management system has enormous advantages in day-to-day operations and has already revealed further savings potential. For example, KÜBLER experts were able to provide Dexion with important savings tips for regulating the switch-on and switch-off times. Further relevant savings opportunities were also uncovered in areas that go beyond pure heating operation. In Laubach, these were high energy losses due to excessively long door opening times - a problem that exists in many production halls and warehouses and can be controlled by specially developedKÜBLER software modules. Dexion wanted to take over the actual control of the system itself. Two digital control systems from the new and patented KÜBLER CELESTRA line were installed especially for this purpose. The production hall is divided into 10 heating zones. These can now be individually controlled and regulated in a very simple and self-explanatory manner, depending on the shift operation and heat requirement. For Dexion, this offers unprecedented flexibility to adapt the heating process to different workloads and to be able to intervene at any time. Dexion: "We would not have been able to meet the heating comfort requirements of our hall situation any other way."

At a glance: The KÜBLER Group

KÜBLER GmbH is an internationally active group of companies and is regarded as a pioneer and innovation leader in modern infrared heating technology. The core business is the development and production of highly efficient premium technologies for energy-saving and climate-friendly hall heating. KÜBLER offers an exceptionally wide range of products for almost all types of halls and room environments. Founded in 1989, the group of companies employs over 120 people and is one of the leading companies in the industry in Europe with locations in Ludwigshafen, Dresden, Hagen, Hamburg, Prague (Czech Republic), Fegyvernek (Hungary) as well as numerous foreign agencies and a nationwide service network.KÜBLER products and development services regularly receive awards. National and international prizes include the Federal Prize for Outstanding Innovative Achievement from the Federal Ministry of Economics, the Bavarian State Prize and the German Sustainability Award. KÜBLER received this highest German award for sustainable entrepreneurship for the special energy efficiency of the H.Y.B.R.I.D system in the category "Germany's most sustainable product". In 2018, KÜBLER was honored for the third time with the Innovation Award of the State of Rhineland-Palatinate, awarded for the innovative WÄRME 4.0 digital hall heating system.

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