Energy Management for Industrial Plants

Energy management in the production of painting and decorating tools made of moulded plastic

Solutions for significant energy savings which would result in lower production costs and a reduction in CO2 emissions were developed for the production processes examined under the project.



FIA GmbH in Wangen im Allgäu manufactures painting and decorating tools from a variety of moulded plastics and nonwovens.

Large amounts of energy are required for injection moulding, drying, flame treatment and packaging, and the resulting heat emissions are very high. These heat emissions place an unwanted thermal load on the production hall and thus on the people working there.

If the temperatures climb too high in the summer months (38°C), productivity falls and the quality standards for the products cannot be met.

Project objectives:

   • To create better working conditions by reducing the temperature
   • To reduce heat emissions
   • To lower the cost of primary energy
   • To reduce CO2 emissions

Energy management was to be introduced to counter the rising cost of energy and the resulting increase in the cost of production. To this end the current status was recorded, and possible solutions developed and assessed.


Some of the measures proposed would reduce gas and electricity consumption and thus be of financial and environmental benefit:

Electrical devices:

Shrink tunnels:
The shrink tunnels are heated electrically and emit great amounts of heat into the production halls, making production conditions worse in the summer and providing extremely expensive heating in the winter.

   • It is urgently recommended that the amount of air exchanged with the surroundings is reduced. This would lower the electricity needed for the shrink tunnels and to cool the halls in the summer months.

Refrigeration unit for computer-controlled air conditioning:
The computer-controlled air conditioning system releases the heat into the production hall throughout the year, reducing the amount of heat needed in the winter, but heating the production hall up considerably in the summer when operating hours are longer. The high temperatures inside the building also mean that the air conditioning works with a lower COP, i.e. efficiency.

   • A temperature-controlled and air-conditioned exterior condenser and the installation of a switch-over valve would allow the heat to be released according to need and electricity consumption to be reduced at the same time.

Granulate dryer:

   • The dryers should be prevented from emitting warm, moist waste air into the production hall.
   • Hot pipes from the dryer to the granulate container should be insulated.
   • The time-based regeneration of the absorber should be converted to a needs-based system.

Electrical heating of injection moulding granulate:

   • Insulation should be installed in the system to lower the unnecessarily high radiation of heat.

Gas-fired devices:

The exhaust ducts discharge 7000 m³/h to the atmosphere at temperatures of between 50 and 270°C. As the ducts are not insulated, some of this heat is released into the production hall.

   • The ducts should be insulated to reduce the heat load placed on the hall during the summer. A spiral-tube heat exchanger should be used to recapture as much heat as possible during the winter.

Project Participants

Implementing Institutions


Cooperation Partner

LinkSIMAKA Energie- und Umwelttechnik GmbH

More Project Informations

Project period: 2005 - 2007

Project region: Germany (Baden-Württemberg)

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Source: Landesanstalt für Umwelt Baden-Württemberg