3A Composites is one of the world's leading manufacturers of high-quality plastic panels, aluminum composites and other composite materials. Around 4,500 employees in 40 countries around the globe work to offer customers market-leading solutions for demanding tasks in architecture & design, display, industry and mobility with premium products such as ALUCOBOND®, AIREX®, DIBOND® and CRYLON®. 3A Composites is part of Schweiter Technologies and as such is committed to the high sustainability standards of the global player. In 2023, when the heating of the new lightweight hall for coil storage, energy efficiency, thermal comfort and durability were the decisive criteria.
The projects
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 products are produced as huge, sometimes 11-meter-long ALUCOBOND® panels are shipped all over the world. 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 Alusingenplatz 1 site with steam for processes and heat. After the decision was made to phase out coal energy and dismantle the power plant on the site,
The highly efficient infrared dark radiators of the KÜBLER MAXIMA brand have far exceeded the expectations of 3A Composites Singen: only 70,000 instead of 180,000 kWh of annual energy consumption are enough to keep the double logistics hall reliably warm in the winter months.
The question of heating also arose anew for 3A Composites. The team, led by Donath Pochaba (Head of Engineering and Strategic Projects at 3A Composites), planned the heating of the two hall projects and had very clear ideas about the criteria that needed to be met:
- 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
- Logistics hall 1 and 2 (lightweight construction)
In the new 55 x 35 meter double hall for coil storage, eight gas-powered infrared heaters from the MAXIMA line were put into operation in April 2023 at a height of around seven meters. With over 80 percent infrared efficiency, the high-efficiency class from KÜBLER is probably the most efficient dark radiator technology. The systems reliably and evenly supply the two hall areas with heat at very low energy consumption without causing air movement or stirring up 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. However, this option is not currently attractive due to the high electricity prices.
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 to the heating mode 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 to prevent 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.
- 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
Results
The MAXIMA systems are controlled by the patented CELESTRA digital control system, which was specially developed for the optimum and energy-efficient operation of infrared indoor heating systems.
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 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. The switch to the CO2The use of natural gas as a low-carbon energy source has reduced emissions in the existing building by over 74 percent!
