OREANDA-NEWS. Stuttgart – energy efficiency is increasingly becoming necessary to be able to safeguard the future of manufacturing enterprises sites. Compared to other countries, the energy costs of many sectors in Germany represent a share of 5-8% of the total costs of product manufacturing, which is rather high. Efficient usage and the reduction of energy costs is thus an essential competitive factor. In order to be able to identify all potentials, take advantage of them and profit from savings, a holistic approach is required. With the "energy efficiency system for manufacturing enterprises", Bosch has developed a modular service portfolio especially for the requirements of industrial enterprises. "Through our own experiences with plants and our expertise in the area of energy, we show enterprises how they can achieve a competitive advantage through energy efficiency." says Michael Blichmann, manager of Bosch Energy and Building Solutions GmbH. "For example, we reduce large energy cost pools and vary fixed costs."

Holistic approach ensures high savings
The energy efficiency system includes a comprehensive range of services: from energy strategy consultation and energy savings optimisation, by means of transparent description of energy flows, to energy optimisation of the manufacturing process and the infrastructural energy supply. An essential factor for success in this regard is the solutions that intelligently combine the production and distribution of process energy as well as the efficient usage of mechanical energy during the manufacturing process. Michael Blichmann: "We develop individualised energy solutions based on the requirements of the enterprise and are able to provide all forms of usable energy." Thus Bosch combines, among other things, the generation of pressurised air, heat and cold in a decentralised solution, which, in the case of actual energy saving parameters for enterprises, is especially attractive and economical.

Reduction of usage during the manufacturing process
Although the analysis of energy requirements for the manufacturing process is frequently underestimated, it is essential for the improvement of energy efficiency. It is precisely here that consumption can be significantly reduced and costs permanently lowered with a short return on investment period. By means of different measures, such as targeted deactivation management or the reduction of energy usage for machine groups, the base load, for example, can be reduced significantly. To recognise and implement the potentials a comprehensive know-how is necessary. This is where Bosch has the advantage of many years of practical experience and has achieved outstanding savings in its own plants. Thus the optimisation of a machine group on one site alone leads to a reduction of 25 % of energy usage – the consumption requirement of approximately 1400 single-family homes. Even Getrag Untergruppenbach, an international system provider of gearboxes for passenger cars and light utility vehicles, relies on the special knowledge of Bosch. Together with the responsible parties, high savings potentials were identified at the Neuenstein site. After the implementation, the total energy consumption of the plant was reduced by 5 percent annually with a return on investment period of 2.5 years.

High savings potentials for process energy
The fruit juice producer, Albi, in Bergh?len profits from a reduction of 5 percent of energy costs annually – and this has been achieved despite its production. Through the Bosch optimisation, the required energy on the site has been generated by means of a highly-efficient combined cooling, heating and power (CCHP) systemsince 2014. The complete concept was planned by Bosch, implemented for immediate use, set up and the installations are now operated efficiently over a long-term period of time. "For us, profitability, with aspects such as economical usage of primary energy, cheap primary energy purchasing, high efficiency of used primary energy types, as well as reduced environmental pollution, were the priorities", says Norbert Reuss, member of Albi Management, Purchasing, Production and Technology. “The concept of Bosch takes all the relevant aspects into account, is technically well-conceived and promises good economic results.” The Bosch experts take into account all strategic, organisational and technical fields of action. "The savings potentials in the enterprise are extremely high. We see this every day in our projects. Our goal is always to be able to reduce the energy consumption sustainably – without loss of product quality, comfort and security of supply" says Michael Blichmann. In addition to attractive services, the customers receive a comprehensive service provision package from Bosch. "We consider ourselves a long-term energy partner and also offer attractive financing and contract models. In particular, we provide a guarantee that the savings potentials identified by us are realised – so that the companies are on the safe side", he concludes.