Energy Efficiency@festo
Energy Efficiency@festo
2
Hands-on energy efficiency
3
We are energy saving innovations.
We are sustainability in production.
We are the catalyst for your efficiency.
4
Energy efficiency in focus
We are the catalyst for your efficiency. With us, you can rely on technical experts and efficient technologies
that will ensure your machines and systems consume fewer resources and less energy.
This reduces your CO2 emissions as well as your operating costs. And it leads to increases – in the sustainability
of your production processes and your company’s productivity.
Focus
Energy
Energyeffi-
efficiency
ciency
Services
Industrial training • Festo Energy Saving Services: the service package
• Take advantage of the expertise of our sales to make the best possible use of potential savings.
engineers and energy efficiency consultants. • From compressed air audits to the implementation
• Benefit from Festo Didactic’s close links to of energy-saving solutions, our specialists support
industry and its training portfolio. you with tailor-made services.
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Page 5 Page 14
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Page 38 Page 52
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An eye to the future
Ecological footprint
3 x
If we continue to live as we do
now, we will need nearly 3 Earths
to support our lifestyle in the
year 2050. [2]
4°
Climate change
The temperature of the Earth’s
atmosphere is four degrees
higher than it was before the
Sources onset of industrialisation. [4]
[1] G erman Federal Environmental
Agency, http://www.umweltbun-
desamt.de/, 2012.
[2] L iving Planet Report of the WWF,
2012.
[3] T he future of energy, an initiative
of the German Federal Ministry of
Education and Research, 2013.
[4] R eport issued by the World Bank,
Turn down the heat: climate
extremes, regional impacts, and
the case for resilience, 2012.
8
70
,000,000,000
Dwindling natural resources
During the last 30 years, world-
wide extraction of natural
resources has doubled to a vol-
ume of roughly 70 billion tons
per year. [1]
33 %
Decreasing biodiversity
Studies done in 2008 show that
animal populations around the
world had decreased on average
by 33% in comparison with levels
reported in 1970. [2]
80 % Fossil fuels
80% of worldwide energy require-
ments are currently met by fossil
fuels with limited reserves. [3]
9
Current facts: energy consumption patterns
in Germany
How much energy is currently being consumed in Germany and how is consumption distributed? How much
of this consumption is generated by industrial applications which are relevant for Festo? The two graphics
below provide an overview and reveal that in the industrial sector too, significant energy saving potential can
be exploited.
Energy consumption
according to industry
application in 2011 (values
Heating: 8% (207.3 PJ)
Hot water: 1% (23.9 PJ) specified in % and PJ)
Other process heat: 66% (1729.7 PJ)
Air conditioning (electricity): 1% (16.8 PJ)
Other process refrigeration (electricity): 1% (17.9 PJ)
Mechanical energy (electricity): 21% (558.7 PJ)
Information and communication technology
(electricity): 1% (33.7 PJ)
Lighting (electricity): 1% (35.9 PJ)
10
Opportunities are available: grab them!
There are lots of opportunities for increasing energy efficiency in your production processes – they only need
to be exploited! Take the time to search for possible approaches – it pays off. Take advantage of the following
typical opportunities:
ISO 50001
Energy
Management
Note
11
12 ways to save energy!
12 different measures and ways to successfully save energy In the opinion of our experts, these measures pro-
mote quick and simple implementation of suitable optimisation measures, for example as described in VDMA
standard sheet 24581 (Pneumatic fluid power - Application notes for the optimization of the energy efficiency
of pneumatic systems). The following examples show best-case scenarios of how much you can save with the
help of each measure.
Our tip: Ask for advice from the experts at Festo who are highly knowledgeable with regard to energy efficiency
and have mastered the implementation of this integrated approach.
Reduce friction
-15% Use air-saving circuits
-60%
• Use low-friction components V • Handling vacuum with
Mini-slide DGSL V monitored switch-off
t use OVEM
12
Reduce the pressure level
-22% Reduce leakages
-20%
4 6 • With a pressure regulator • Routine leakage detection,
2 8 • Return stroke with reduced condition monitoring
bar/psi pressure 6 3 bar Energy Saving Services
MS series, VABF
Recover energy
-10% Switch off power
-10%
I
• Save braking energy in the • Leakages reduced by up to 10%
coupled intermediate circuits • In this case for the entire com-
Multi-axis controller CMMD pressed air system
P
… to systems
13
Functional chains of pneumatic systems
High energy prices, rising cost pressure and a growing awareness of climate protection have turned energy
efficiency into a key business task. Pneumatic systems, too, offer attractive potential savings in this respect.
The key to success lies in taking a comprehensive look at pneumatic systems.
14
Compressed air distribution Compressed air applications
Compressed air systems are sub- There are numerous opportuni-
ject to continuous change, as, for ties for saving energy when using
example, production systems are compressed air applications.
converted or expanded, the Detailed information can be
amount of air is increased or found from page 18 onwards.
lines are added. This results in
networks which are not optimally
laid out and installed, in some
cases with significant pressure
losses.
15
Energy efficiency in pneumatic applications
Energy recovery
for 5% of the
drives
Tubing
lengths
shortened
by 50%
Pressure reduced
4 6 from 6 to 5 bar
2 8
bar/psi
-53%
-€3000
Energy and cost savings,
and CO2 reduction
-13 tons CO2
16
… in the food industry – forming, filling and sealing
t t
Tubing
lengths
shortened
by 50%
Energy recovery
for 5% of the
drives
-46%
-€2600
Energy and cost savings,
and CO2 reduction
-11 tons CO2
17
The payoff
How can Festo help you to Energy efficiency measure Description Working parameters
optimise your application?
Annual savings
one size smaller
m m
Annual savings I Switch off power Switch off for 3rd shift
> €1000 (20% leakage)
P
€500 to €1000
Use air-saving circuit 50% of the drives with return stroke
V
€100 to €500 V at 3 bar
t
< €100
18
Sample applications with potential savings
30 15 60 6 1 5
6% 6% 6% 6% 6% 6%
€350 €1,674 €19 €342 €270 €541
1.48 tons CO2 7.07 tons CO2 0.08 tons CO2 1.44 tons CO2 1.14 tons CO2 2.28 tons CO2
3% 3% 3% 3% 3% 3%
€166 €805 €9 €163 €127 €253
0.70 tons CO2 3.40 tons CO2 0.04 tons CO2 0.69 tons CO2 0.53 tons CO2 1.07 tons CO2
8% 8% 8% 8% 8% 8%
€482 €2,304 €27 €470 €372 €744
2.03 tons CO2 9.73 tons CO2 0.11 tons CO2 1.99 tons CO2 1.57 tons CO2 3.14 tons CO2
19
Pneumatic drives – tips
There are numerous options for saving energy consumed by pneumatic drives. These are always advantageous
where sustained holding force is required. The application’s features also play an important role in selecting a
pneumatic solution. The following should be taken into consideration:
• Design safety functions correctly – • Reduce air consumption – if possible, use single-
accumulation reduces economic efficiency. acting cylinders.
m m m m
• Size pneumatic cylinders correctly. Oversized
• Keep tubing lengths as short as possible – cylinders consume more compressed air than
the shorter they are the less energy is lost. necessary.
• Misalignment causes stress on the seals and • Use cylinders with round piston rods in preference
bearings. Leakage and wear can be minimised to those with oval and rectangular piston shapes
by flexibly coupling the drive and the load. as they always have relatively high leakage rates.
• Drive-guide combinations provide ideal operating
• Reduce moving masses as much as possible. characteristics, while going easy on the seals.
This helps to avoid high leakage rates.
• Suitable hard scrapers on the piston rod reduce
wear in dusty environments.
20
Working it out for you: correct sizing
-35%
Correct sizing of pneumatic • A diameter of 40 mm has been
drives used thus far.
m m
• The diameter is reduced to
Software tools are used in order 32 mm because the application
to select the right system compo- can still be operated with a
nents for the application with smaller cylinder without any
minimal effort. The components problem.
used are thus only as large
as they really need to be for the Air consumption is reduced
application. Oversizing is by 35%.
avoided. Unnecessary energy
consumption due to excessive
potential force can be prevented.
Reduction to the next smaller
size decreases energy consump-
tion by roughly 35%.
21
Pneumatic drives – products
Lightweight materials, continuous improvement of reliable seal concepts and the development of hermetically
sealed drive systems: these are three decisive factors for low energy consumption during operation. Festo’s
portfolio includes a broad range of pneumatic drives that have precisely these attributes.
In particular the numerous guided drive combinations deserve special mention, as they help customers avoid
misalignment and thus potential leaks as well.
Benefits
• High precision and load capacity
thanks to innovative bearing
technology
• Simple layout and concept pro-
vide good availability and very
short delivery times
• New function variants for a
great variety of customer appli- -53%
cations
22
Compact cylinder ADNP
Especially lightweight cylinder
due to polymer end cap
• Dia.: 20 ... 50 mm
• Stroke: 5 ... 80 mm
23
Valves and valve terminals – tips
In the field of pneumatics, valves function as switching and control components. The drives connected to them
can only be operated efficiently if the valves are correctly sized and actuated.
• Combine valve sizes correctly on the valve • Use reversible operation: pressure regulators
4 6
terminal. 2 8 upstream of the valves allow exhaust air to
bar/psi
m m
escape from the cylinder without resistance. It
• Keep the number of connections/fittings as low doesn’t have to be exhausted by the regulator.
as possible: valves on manifold blocks, or in • Create different pressure zones in valve terminals
general on valve terminals, reduce potential leak- in order to save energy.
ages. • Use modern proportional valves with pilot control
based on piezo valve technology to control pres-
I • Use valves whose solenoids are actuated with sure levels and flow rates. This reduces energy
reduced holding current. consumption considerably.
P
40,000
Compressed air consumption [Nm³]
35,000
€200/year
30,000 €230/year
25,000
20,000
15,000
10,000
5,000
0
Ø6x1 Ø8x1.25 Ø10x1.5 Ø6x1 Ø8x1.25 Ø10x1.5 Ø6x1 Ø8x1.25 Ø10x1.5
L = 15 m L=8m L=3m
The graph shows the influence of different tubing lengths and tubing diameters
on compressed air consumption. This sample calculation is based on 10 clamp-
ing cylinders in automotive production at 1500 cycles a day.
24
Working it out for you: reduced pressure during the
return stroke
In many applications, full force is only required in one direction. Pressure can be cut in half for the return
stroke without causing any problems. This is especially easy to achieve if valve terminals with vertical-stacking
regulators are used. Compressed air consumption can be reduced by more than 20%.
-22%
Adjust the pressure level to • Air consumption of a standard
4 6
meet the requirement 2 8 cylinder DSBC 32-500 during
bar/psi
normal operation at 6 bar:
If valve terminals with vertical‑ approx. 5.1 Nl
stacking regulators are used, the • Air consumption of a standard
pressure level can be easily cylinder DSBC 32-500 when
adjusted to the application’s advancing at 6 bar and with
actual requirements. This makes, pressure reduced to 3 bar dur-
for example, a return stroke with ing the return stroke: approx.
reduced pressure easy to imple- 4.0 Nl
ment.
All in all, air consumption is
reduced by 22%.
Before
32 mm, 500 mm 5.1 Nl
6 bar
6 bar
After
32 mm, 500 mm 4.0 Nl
6 bar
3 bar
25
Valves and valve terminals – products
Nowadays a great variety of valve functions are performed using valve terminals. This saves time and effort
during installation – and it is important for the prevention of leakages in pneumatic circuits. Valve terminal sys-
tems tested for leaks, solenoid coils with electronically reduced holding current, the creation of pressure zones
and integrated pressure regulators: valve terminals with these features reduce energy costs in the long term.
-22%
26
Δp ISO valve terminal VTSA
P
Unique worldwide – 5 valve sizes on
t
a single valve terminal
• Very high flow rates – up to 4500 l/min
• Reverse operation of valves and pressure
regulators
• Simple implementation of pressure zones
• Diagnostic concept
• Vertical stacking
27
Gripping and vacuum – tips
Of course the extensive product range from Festo also includes perfectly matched mechanical and vacuum
grippers for the front unit. In some cases this results in massive energy-saving potential.
Gripping Vacuum
• The gripper must be correctly sized. Oversized Install the vacuum generator as close as possible
grippers consume more compressed air than to the application.
m m
necessary. Vacuum suction nozzles are the ideal solution for
this purpose.
• Use shortest possible tubing lengths, i.e. position • Avoid long tubing lines between the vacuum
the valve as close as possible to the gripper. generator and the suction gripper.
• Please note that dead volume in the tubing fre-
quently accounts for a large percentage of overall • Powerful vacuum or high suction rate? Select the
consumption, especially where gripping with right suction nozzles for the application in ques-
m m
small volumes is involved! tion.
• Short evacuation times reduce air consumption
• Use pneumatic grippers in moving applications. at the vacuum generator.
They are lighter than electric grippers, and they
reduce weight and save energy as a result. • Vacuum generators with air-saving circuit are
V
• Use pneumatic grippers for long holding times. V capable of saving large amounts of compressed
t
With pneumatic grippers, gripping force is availa- air in many cases.
ble for as long as needed – without any additional
energy consumption. Electric grippers are con- Δp
• Check exhaust air silencers in vacuum generators
trolled and require additional holding current. P
for contamination on a regular basis!
t
28
Working it out for you: air-saving circuits in
vacuum applications
Constant vacuum pressure is not absolutely necessary for reliable holding of objects. Continuous air consump-
tion can be avoided by using an air-saving circuit, especially in the case of smooth surfaces. Savings amount
to roughly 60% of previously required volumes of compressed air.
-60%
Switch off vacuum generation V
• The compressed air supply is
intermittently V shut down by a solenoid valve,
t
and vacuum pressure is moni-
The vacuum suction nozzle OVEM tored by a sensor.
with integrated air-saving circuit • The air-saving circuit is espe-
monitors vacuum pressure. When cially efficient in the case of
the predefined level is reached, smooth surfaces, and reduces
the vacuum generator is air consumption by up to 60%.
switched off until the specified
vacuum pressure value is once
again exceeded.
Vacuum pressure p
-0.7
-0.5
Energy
savings
29
Gripping and vacuum – products
Space-optimised, lightweight components for gripping and vacuum applications provide great
potential for increasing energy efficiency at the front end.
Benefits
• Compact design
• Integrated vacuum monitoring
with air-saving circuit
• High-performance suction and
air-jet functions with optimised
vacuum generator nozzles and
power module
• Condition monitoring with
OVEM increases process relia-
bility and prevents machine
downtime because it monitors
evacuation and ejection times
during every cycle and automat-
ically generates error messages.
-60%
30
Parallel grippers HGPD
Sturdy, powerful and lightweight
• Sealed gripper (IP65) for harsh environments
• No need for additional sealing air
• Easy to clean
Vacuum generator VN
Minimal space required
• Lightweight technopolymer housing
• Can be used directly in the work space
• Electrical and pneumatic actuation
• Max. vacuum: 93%
31
Compressed air preparation and energy monitoring – tips
Energy-efficient pneumatic applications can only be achieved with suitable compressed air quality in accordance
with ISO 8573-1:2010. It is therefore crucial to take certain parameters into consideration.
The following questions need to be clarified when designing a decentralised compressed air preparation system:
What is the maximum required flow rate?
Connection size?
Do all consuming devices need the same compressed air quality?
What is the quality of the compressed air supplied by the compressor?
I • Whenever possible, switch off the air supply • Decentralised compressed air preparation directly
during machine standstills, at the end of shifts, at the system reduces the risk of components
P
during breaks etc. being contaminated. Moisture, contamination
and oil have a negative effect on seals and wash
• When higher pressure levels are required at spe- the initial lubrication out of the components.
4 6
2 8 cific points within the network, use pressure • Tubing material which is suited to the environ-
bar/psi
boosters instead of increasing pressure through- ment prevents chemical, physical and microbial
out the entire system. damage.
• Use only suitable tools when cutting tubing to
Δp • Carefully check the need for filters, because every length.
P
filter stage reduces the flow rate and increases • Fittings with modern sealing rings and support
t
the pressure drop. Follow the motto: “as much as functions ensure leak-proof, reusable connections.
necessary, as little as possible”. • Monitor all air consumption. Countermeasures
• Timely replacement of filter elements in service are only possible if you know how much com-
units prevents unnecessary flow resistance. pressed air is used.
• Use a multiple distributor instead of a series of
T-branches. The pressure drop is greater with
in-line T-connectors than with a multiple distribu-
tor.
32
Working it out for you: air supply switched off during
standstills
World’s first: the energy efficiency module E2M. The module is used to save energy in production systems that
automate processes which are powered by compressed air. E2M provides active, intelligent control of the
compressed air supply by shutting it off during system standstills and restarting it for production. Losses due
to leakages are therefore limited. The module reads out relevant measured values from the machine’s control-
ler such as pressure and flow rate via a bus system. This makes it possible to monitor the system in a specific,
targeted way.
-20%
Eliminating the flow of supply • Assembly system with 20%
air in compressed air systems at leakage
standstill • Daily utilisation: approx.
10 hours production and
At weekends and during breaks, 14 hours standby
if the machine is at a standstill • System consumption per day
air supply to the system is shut without E2M: 1242 cubic Nm
down automatically, but working • System consumption per day
pressure (P2) is maintained. with E2M: 970 cubic Nm
Pressure losses due to leakages
are reported. The system is Savings: 20%
started up manually when
required. This reduces com-
pressed air consumption by up
to 20%.
33
Compressed air preparation and energy monitoring –
products
Optimally sized intelligent service units provide just the right amount of clean compressed air, and also moni-
tor the system’s consumption levels. Using the right components for distributing the compressed air can save
a great deal of money.
Benefits
• Zero compressed air consump-
tion in standby
• Checks the system for leaks
• Ensures maintenance in the
event of leaks
• Monitors relevant process data
-20%
34
Air flow analyser
Autonomous measuring system with data logger
for recording flow rate and pressure directly at the
system
• Easy to install
• Software for evaluating and documenting data
• Measuring range: 30 ... 3000 Nl/min
35
Gain time – with Festo engineering tools for
pneumatic solutions
Festo’s customers have easy access to a networked, digital customer information system for everything from
product selection, design and ordering to outstanding after-sales support. The electronic catalogue with inte-
grated engineering tools and the online shop are perfectly set up for a wide range of requirements – and they
take energy efficiency requirements into special consideration.
36
Pneumatic drives – tools
37
Electric automation infrastructure
High energy prices, rising cost pressure and a growing awareness of climate protection have turned energy
efficiency into a key business task. Pneumatic systems, too, offer attractive potential savings in this respect.
The key to success lies in taking a comprehensive look at electric systems.
38
Application
The range of applications is very
diverse. However, most systems
consist of three main components:
a servo controller or a control
unit regulates or controls the
system. An electric actuator,
usually a rotary or linear electric
motor, converts the electrical
energy into mechanical drive
power. The third component, the
mechanical system, converts this
into the required motion.
39
Energy efficiency in electric applications
Regenerative Reduce
braking moving
loads
I Shut down
during lengthy
production
P breaks
-42%
-€643
Energy and cost savings,
and CO2 reduction -3 tons CO2
40
... in the solar and flat-panel industry
Efficient Reduce
actuation moving
and control loads
Size drives
correctly
m m
-35%
-€570
Energy and cost savings,
and CO2 reduction -2.7 tons CO2
41
Electric drives and axes – tips
Where electric drives are concerned, there is plenty of scope for selecting a suitable solution. Here too, it pays
off to consider the efficiency of the overall system and to reduce energy consumption wherever possible.
Below are several tips on how this can be achieved:
• Reducing the moving load has a direct effect on • Adapt the drive technology to the task:
energy consumption. use spindle drives for high forces, or toothed belt
• In the case of vertical applications with large and direct linear drives for high dynamic
loads, it may be helpful to use gravity compensa- response.
tion (e.g. a pneumatic spring). • Use holding brakes for long holding times.
• Designing the drive train as a whole avoids the
• Service drives and axes regularly in order to accumulation of safety factors.
reduce frictional loss.
• Low friction components minimise unnecessary • Rigid mounting of the axis and the motor reduces
losses. vibration and thus unnecessary control effort as
• Eliminate any unnecessary gear units if possible. well.
42
Working it out for you: reduced moving loads
Where electric drives are used, moving loads play a significant role with regard to energy consumption.
The payload is often only a small part of the moving load because cable chains, guides, workpiece carriers and
motors also have to be moved. Reducing the moving loads can significantly influence energy consumption.
M2 ZR
43
Electric axes and motors – products
Energy efficiency is always part of the package with electric cylinders and drives from Festo as they are per-
fectly matched to the motors and controllers and are never under- or oversized thanks to the sizing software.
-20%
44
With EPCO you always get the right combination.
• Fully assembled, optimally matched
m m
• 2 operating modes
−− Servo system: closed-loop operation with
optional encoder
−− Cost-optimised: open-loop operation without
encoder
• Possible motor positions
• Numerous mounting and attachment options
• Easy to clean thanks to CleanLook
45
Controllers – tips
The areas of open- and closed-loop electric control also offer various options for saving energy. These include
efficient closed-loop control, energy recovery and shut-down during non-productive phases.
• Where several moving axes are used, couple the I • Wherever possible, reduce the controller’s energy
controllers’ intermediate circuits in order to make consumption during breaks and standby time, for
P
more efficient use of recovered braking energy. example by switching it off.
• In the event of a lengthy production standstill,
• Use efficient power supplies. completely shut down the electric drives and the
• Optimised controller settings prevent system controller.
vibration and unnecessary energy consumption.
46
Working it out for you: energy recovery
In many applications electric drives not only have to accelerate loads, they have to actively decelerate them as
well. This braking energy can be reused under certain circumstances, thus making it possible to save electrical
energy.
-9%
Reuse energy by means of inter- • Handling task with 2 moving
mediate circuit coupling toothed belt axes without cou-
pling the intermediate circuits
In applications in which the in comparison with a system
acceleration and deceleration including coupling of the inter-
phases of different drives take mediate circuits
place simultaneously, inter
mediate circuit coupling can be Energy consumption is reduced
used to recover braking energy. by 9%
Servo controller 1
~
Network
= Motor
~
=
~
Network
= Motor
~
=
Servo controller 2
47
Electric controllers – products
A broad-ranging portfolio of controllers for all types of applications and in different performance classes makes
it easy to select the most suitable controller every time. In combination with drives and motors, the right energy-
efficient package is thus always available.
Technical details
• Extremely small dimensions
• Intermediate circuit coupling
possible with several control-
lers
• Integrated EMC filters
• Automatic actuation for a hold-
ing brake integrated into the
motor
• Can be expanded to include
an STO function by adding a
plug-in module
-9%
48
Motor controller CMMO-ST
Closed-loop servo controller as a position controller
for stepper motors.
I • Smooth running
• Monitored safe positions
P
• Minimal heat build-up
• Supports safe torque off (STO)
• For Performance Level e (PL e)
• 2 parameterisations
−− Integrated web server
−− Festo Configuration Tool FCT for up
to 31 motion steps
49
Gain time – with Festo engineering tools for electric
solutions
A networked, digital customer information system is the key to energy-efficient electrical solutions. The elec-
tronic catalogue with integrated engineering tools and the online shop are optimally designed for a wide range
of requirements – and they take energy efficiency requirements into special consideration.
50
Commissioning and operation
Safe standard
Select motor, controller and axis
with just a few clicks. Standard
values are set by the software for
the selected components includ-
ing end position and homing val-
ues, as well as values for maxi-
mum acceleration and travel
speed.
Note
51
Forward thinking, targeted action
High energy prices, rising cost pressures and a growing awareness of climate protection have turned energy
efficiency into a key business task.
Energy Saving Services from Festo offer compressed air users a customised range of services for identifying
and optimally exploiting potential compressed air savings – systematically and sustainably. You’ll find our
experts’ enormous wealth of experience in automation technology and energy efficiency invaluable.
They analyse pneumatic systems from the point of compressed-air generation right on up to the applications
in the plant. They show you how to avoid unnecessary compressed air consumption. And they help you imple-
ment the necessary measures and sustain the achieved savings in the long-run.
Auditing
Determine baseline data and
potential savings throughout the
entire compressed air system
52
Energy efficiency as a service
Industrial training
Transferring know-how to you,
so that you can make your com-
pressed air consumption more
efficient
Maintenance
Maintenance of the optimised
operating state and cost savings
over the long term
Implementation
Implementation of action plans
for a quick return on investment
Note
Engineering
Evaluation of measured data and Please note that not all services
development of detailed action are available in all countries, and
plans that services may be provided by
our local service partners.
Ask your sales engineer.
www.festo.com/ess
53
Energy Saving Services in practice
Results
Identified leaks: 296
Total compressed air loss: 1,625,815 m³ per year
Leakage loss: €29,265 per year
Reduction in annual
CO² emissions: Roughly 160 tons
Total project costs
(including replacement parts): €31,000
350,000
Compressed air costs € per year
300,000
29,265
250,000
10%
200,000
150,000 295,000 265,735
100,000
50,000
0
Before Festo services After Festo services
Savings -10%
Eliminating the leaks resulted in
-€29,265
a 10% reduction in compressed Energy and cost savings,
air consumption. and CO2 reduction -160 tons CO2
54
What our customers say
At Tate & Lyle, a global manufacturer of ingredients for food production, the experts from Festo
have been able to fix leaks which were causing compressed air losses of 6000 litres per minute.
“We’re very satisfied Tate & Lyle’s 30 production loca- Focus on leakage detection
tions convert all kinds of raw “Festo checked our systems and
with Festo and its materials into high-quality ingre- discovered lots of leaks”, explains
Energy Saving dients such as glucose syrup. Dubbeld. “All in all we were losing
The company faces high levels of 6000 litres per minute, which
Services. As a result, global competitive pressure. represents roughly 8% of our
we were able to compressed air costs.”
Consequently, Dutch maintenance
reduce compressed manager Remo Dubbeld decided Group-wide energy savings
air consumption by to test all the company’s com- planned
pressed air systems. “We have our This tremendous success in the
about 8%.” own energy saving programme, Netherlands aroused interest at
which has now been perfected other Tate & Lyle locations.
Remo Dubbeld, thanks to Festo’s Energy Saving “I told colleagues at other plants
Maintenance manager Services”, says Dubbeld. about Festo’s Energy Saving
Tate & Lyle, Netherlands Services. We’re now planning to
implement these measures in our
other European plants as well”,
says Dubbeld.
Customer
Tate & Lyle, Koog aan de Zaan,
Netherlands, worldwide manu-
facturer of ingredients and solu-
tions for the food and beverage
industries and for other sectors
Leakage detection in the plant in Koog aan de Zaan. Detected leaks represent
about 8% of total compressed air costs.
55
We make you more productive
Festo Didactic: because knowledge makes you more productive. With more than 40 years of experience and
over 430 specialists, we offer skills development training, qualification and consulting services in roughly
80 countries around the globe. Festo Didactic is the world’s leading supplier to technical educational institu-
tions, as well as a provider of consulting and training services for industry. We’ve equipped more than
36,000 educational institutions with our hardware. Every year, more than 42,000 participants attend around
2,900 Festo Didactic seminars. And we’re committed to promoting young talent too. That’s why we’ve been a
sponsor and partner to the international WorldSkills initiative – the world’s largest vocational education and
training platform – for more than 20 years.
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Industrial training
PN361 – Energy saving in Saving energy is becoming more Target groups Outcomes
pneumatic systems and more vital. In factories and Operators, maintenance staff, The participant:
even small workshops, the intel- engineering, designer, trainers understands the relationship
ligent use of energy sources and between consumption and costs
rightsizing and selection of com- Contents of energy sources
ponents can save time and sub- • Costs of compressed air with can apply efficiency measures in
stantially cut cost and waste. measurements the preparation, distribution and
Compressed air is a key energy • Costs of leaks consumption of compressed air
source for industrial production • Compressed air consumption is able to correct faults that
and offers huge potential for of various circuits cause efficiency waste
cost-saving – from production to • The cost of oversizing and can apply efficiency measures in
consumption. Savings begin by undersizing components pneumatic circuits
paying attention to the people • Rightsizing for efficiency can select efficient components
working with compressed air. • Energy efficient circuits for various applications
This course focuses on peoples’ • Correcting the faults that cause is able to measure the air con-
attention to costs and improve- efficiency waste sumption of various pneumatic
ments the areas of compressed applications
air production, preparation and can improve the lifetime of vari-
distribution, as well as on the ous pneumatic components
design of pneumatic circuits. This
course particularly meets the
training needs of customers who
have already benefited from the
Festo Energy Saving Service.
Note
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Together for more energy efficiency
Achieve more through cooperation: maximum possible energy efficiency can only be attained if the research
efforts and the know-how of leading scientists, engineers, institutions and companies are combined as theory
and practice go hand in hand in this respect.
This is the reason why Festo is actively involved in numerous research projects, initiatives and collaborations.
See for yourself!
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Save
compressed
air!
Saving energy is easier than ever before thanks to the MSE6-E2M which automates
energy saving in compressed air systems. The intelligent service module monitors and
regulates the compressed air supply in new and existing systems – fully automatically. www.festo.com
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Productivity