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Compressed air in the plastics industry

Gebr. Schwarz GmbH in Rottweil-Neukirch is a state-of-the-art technology company in the field of plastics and tooling technology. Founded in 1966, the company today stands for precise, sophisticated and innovative plastics solutions, both nationally and internationally, with around 200 employees. The company’s philosophy of manufacturing innovative complete plastic solutions according to individual requirements is made possible by involving all partners involved in the process. Gebr. Schwarz develops innovative plastics solutions for the fields of measurement and electrical engineering, sensor technology, healthcare, environmental and energy technology as well as the automotive sector. The basis for this is methodological expertise, many years of plastics know-how, quality systems and state-of-the-art EDP systems in the company.

Challenge

The company uses air compressors in the production of complete plastic solutions. Compressed air is used here as process air for the operation of robot, assembly and measuring systems. With maximum availability, around 2,053,000 m³ of compressed air is generated and provided in the right quality. This places high demands on the compressed air and treatment in the company.

To make production processes even more efficient, a future-proof and efficient compressed air supply is essential. The company is aware of its responsibility towards future generations and the environment. It therefore invests sustainably at the site in order to optimize the plant as well as to use the necessary energy as efficiently as possible. The focus here is also on recovering waste heat for heating purposes.

Solution statement

  • In order to sustainably reduce energy requirements, the pressure level was lowered by over 1 bar.
  • The interaction of all measures resulting from the analysis were implemented to achieve a particularly high level of sustainability. In the compressed air station, too, the compressors that were just sufficient were replaced and switched to highly efficient compressors with minimal redundancy.
  • The KAESER compressors of the ASD series consistently implement the aforementioned customer requirements in operational practice. They use energy sparingly, are quiet, require little maintenance, operate reliably and deliver even better compressed air quality.
  • The KAESER compressed air tank fulfills important tasks in the compressed air station as a storage and buffer medium. By reducing the overall pressure level, it significantly balances the usable buffer volume and thus ensures low load changes of the compressors.

Customer value

  • Thanks to short response times, FILCOM guarantees maximum reliability for the customer. The sustainability of this partnership concept conserves resources and supports the redundancy concept at Gebr. Schwarz.
  • As a user, Gebr. Schwarz GmbH expects high efficiency and reliability from its compressed air supply.
  • By using a heat recovery system, energy that has already been paid for can be used sensibly for heating purposes one more time.
  • An insulated heating pipe ensured maximum energy savings. Here, the equivalent of 6,600 liters of heating oil as well as heating oil costs of € 10,000 could be saved and CO2 emissions reduced by 38 t / year. Electricity consumption was reduced by 26%.

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