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Höcker Polytechnik extraction system reduces power costs by more than 60 per cent

Tiefdruck Schwann-Bagel GmbH & Co KG

A properly functioning extraction and dust extraction system is the backbone of the day to day print shop operation. And it is a gain for every company if such a system runs safely and reliably for more than 20 years. One the largest print shops in Europe, the Tiefdruck Schwann-Bagel GmbH & Co.KG (TSB) in Mönchengladbach has scrapped its old functional system and replaced it with state of the art extraction technology.

It quickly became apparent that this was a good decision. The new low pressure extraction system uses significantly less energy and reduces the power costs by 60% In less than two years the investment in the new extraction system will have been amortised. The new system was developed and built by the HÖCKER POLYTECHNIK GmbH in Hilter near Osnabrück - one of the leading suppliers for extraction and dust extraction solutions for the printing, paper, corrugated cardboard and packaging industry.

The TSB printing company is a specialist in high volume printing and has the most modern production technology. The extraction system, that was built in 1990, had continuously grown with the production. Using transport fans the complete cutting waste of the printing operation was disposed of. The energy consuming fans transported the cutting waste and dust over twelve extractor lines from the farthest corner of the widely spread network of manufacturing buildings to the central disposal room. The resistance that had to be overcome necessitated a high performance fans, and more performance naturally means higher power costs. The production at TSB runs six days per week, 24 hours a day - this meant a high price was paid for the total power of the system of 550kW for the high pressure extraction.

Low pressure extraction as a cost reduction

A new extraction system in 2013 was reason enough to rethink the extraction concept. Tobias Neumann, Manager of Facility Engineering at TSB, sounded out the market for a future-proof solution for his company. Here Marc Biehl from HÖCKER POLYTECHNIK stood out positively with the energy saving low pressure technology. He analysed the existing extraction technology and promised an extraction performance optimised for the operation, dust free workplaces and a power savings potential of up to 50% with his technical concept. HÖCKER was given the order, now the promise had to be kept.

Marc Biehl, Project Manager at HÖCKER POLYTECHNIK: “Installing a new system at TSB was a very ambitious project. During all the project phases we worked very closely with Mr Neumann. Only then was it possible to install the new technology while the manufacturing operation was running. I never doubted our promise to halve the power costs. With the right design low pressure systems can work with lower fan power and additional energy saving features reduce the power consumption even further. As the consumption indicator settled at 230 kW after the start of operation, Mr Neumann’s relief and satisfaction could be felt. Consequently the Höcker company and myself were also visibly satisfied, because we keep our promises.”

Marc Biehl and his team worked flat out on the low pressure extraction system. Filter systems, ducts, pneumatic transport lines and the discharge were newly designed and optimally tuned to the production. Since the beginning of 2014 the new extraction system has proved itself in the day to day operation.

Planning and technology saves more than 100,000 p.a.

Two MultiStar push floor filter systems work remotely in the proximity of the production.
 Three frequency regulated 30 kW fans are in integrated in a space saving manner in the filter attachment providing the low pressure required in the extraction system. Using upstream material separators the paper waste is discharged into container presses. BrikStar V briquetting presses under every filter process the paper dust to briquettes. The complete system works automatically.

An intelligent SPS control centre is the brain of the system and, at the same time, a centre for measuring energy consumption. It controls all the components of the system and attunes their mutual behaviour. Every extraction line can be switched to or off using, for example, pneumatic slides. If a line is switched off, the SPS automatically reduces the total power consumption and regulates the regulates the rpm accordingly. The centre for measuring energy consumption is integrated into the TSB network and, at all times, supply actual and historical consumption data. On average the complete extraction system consumes 230kW (despite additional manufacturing area) that’s a good 300kW less than the old system As a result several100.000€ worth of energy are saved every year.

The advantages of the HÖCKER system at a glance

  • the low pressure system requires less fan power
  • cascade switching and frequency regulation reduce the power consumption of the fans
  • switched off extraction lines reduces the power consumption
  • thermal recycling reduces the costs for heating
  • simple and economical handling through dust-briquetting with BrikStar presses
  • automatic system operation reduces manpower costs
  • fire protection regulations are adhered to
  • work safety regulations are fulfilled
  • energy savings within the project are a significant part of the current EMAS certification

Tobias Neumann, Manager of Facility Engineering, TSB: “At the beginning of the project we were very sceptical as to whether the 50% lower power consumption was realistic and if the low pressure system would function perfectly. We have now been working with the new HÖCKER POLYTECHNIK system since January 2014 and are delighted. Our power costs were reduced by 60% and the manufacturing operation runs perfectly. In particular, the practical implementation of the concept was convincing. The complete new system was installed parallel to our normal business operation. As planned, the machines only had to be stopped for 30 minutes when we switched from the old system to the new system. From the planning phase to the start of operation, the cooperation with Mr Biehl and his installation team was always friendly and impeccable. Top performance!”

(Authors: Marc Biehl and Diethard Beutel)

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