Systematic Energy Management

It all started at the main facility in Weinheim in 2014. In the interim, certificates have documented the introduction of energy management systems conforming to the demanding international ISO 50001 standard at all Freudenberg Sealing Technologies production facilities in Germany. Energy efficiency is being increased, and energy consumption and costs are being systematically reduced. Through the use of energy audits, the remaining German as well as European facilities have also shown that they are in line with the European energy efficiency guideline.

“We have been pursuing these sustainable goals for a long time and have initiated many successful individual measures – but on a rather selective basis. Now we are proceeding systematically. Energy management strengthens our competitiveness,” said Hans Kloos, Energy Efficiency Representative at Freudenberg Sealing Technologies. It also conserves natural resources.

Energy-efficiency teams record energy flows within the company, evaluate consumption, and draft and carry out action plans – not just once but on a recurring basis, which is the standard approach in any management system. “In this way, the issue remains in our consciousness continually. That’s important since great successes can only be achieved with changes in energy-conservation behaviors. Everyone knows that from everyday experience,” Kloos said.

The precise capture of energy consumption in graphs and tables is a proven way to identify the potential for savings. “Efficient energy management is based on efficient energy visualization,” Kloos said. When do load peaks occur and how can they be avoided so the supplier has to hold less energy in reserve? For example, by not ramping up all the equipment at the same time. Or by temporarily shutting down predefined consumers when a load peak is looming.

Thanks to the systematic evaluation of energy consumption, the preheating period for mold plates used in vulcanization can be shortened to the minimum necessary duration, for example. Or the data may show that compressed air or electricity is still being used when an installation is not in operation: Is there a leak in the line? Is the machine still in standby mode instead of being shut down?

“Our goal is to largely eliminate costs that result from unnecessary energy consumption,” said Winfried Heiser, Energy Management System Representative. “Ideally, we then only consume energy if we are really producing parts and services and are thus creating value. This is cost-effective and simultaneously spares the environment since less CO2 is emitted, for example.” In the end, this is the same principle applied in a start-stop system that shuts off the engine when a car comes to a halt. Energy is only consumed when it provides a benefit.