PBS Powder Coating wanted to reduce its energy consumption by at least 10 percent with a power management system. The manufacturer anticipates that the system will save more than EUR 170,000 per year.

PBS Pulver Beschichtung Schreiner GmbH & Co. KG, (PBS Powder Coating), a family-owned, third-generation German company, powder coats more than 2 million square meters of aluminum, cold-rolled steel, and galvanized steel annually.

Because the powder-coating process is very energy-intensive and the company anticipated additional price increases for electricity and oil, reducing its energy consumption was at the top of its agenda. The manufacturer set a goal to reduce its energy consumption by at least 10 percent.

PBS produces on three coating systems comprising eight lines with continuous multi-shift operations. Company staff had no way of knowing exactly how much was consumed and where energy could be saved.  “The only way our employees had to influence energy consumption was to rely on their instincts and experience,” said PBS Managing Director Harald Schreiner.

Power Data Management System Launched

Figure 1:  A Wago power management system allows PBS to monitor energy generation and consumption, including in its newly installed biomass furnace.

To achieve its energy reduction goal, the manufacturer implemented ISO 50001 and DIN EN 16001 operational power management systems. To record the required measurement data quickly and reliably and evaluate it centrally, PBS installed the WAGO-I/O-SYSTEM and its three-phase power measurement modules (see Figure 1).

The power management system was planned and set up by narz systems of Herbstein, Germany, a Wago systems provider that specializes in automation and IT systems. Setting up the power management had to be fast, but also absolutely reliable. Data had to be collected in a small space.

“With a power management system, we now have created a reliable basis for data recording and for control of consumption,” said Schreiner who anticipates that the system will save more than EUR 170,000 per year.

“In the future, we can use the detailed power and production data to optimize further, to modernize systems and achieve additional cost savings,” relayed Manfred Weibgerber, who is responsible for maintenance at PBS.

How Energy Is Recorded

A total of 380 measurement points serve as the information basis for the energy consumption. Distributed across all production areas, they record the consumption data for electricity, heating oil, heat, air compression, effluent, and chemicals. The Wago system and three-phase power measurement modules and other analog input modules record the data for values such as pressure, temperature, and flow.

The power measurement modules are integrated directly into the controller so that no external measurement device is required. The measurement data is collected in nine data recoding islands, pre-processed in the WAGO-I/O-system 750, and transmitted via Ethernet. The data is visualized automatically in the form of charts and reports on a central server.

Energy Savings Becomes Apparent

Employees in each production area have insight into the actual energy consumed via large 40-inch display. “With the large number of measurement points, we now have the opportunity to provide our 175 individual plant workers with precisely the data they need in order to better control their areas,” Schreiner said.

Using the data acquired, PBS has plans for further optimization, including modernizing systems to achieve additional savings. “The power management technology has proven itself,” Schreiner said. The WAGO system uses open protocols and industry standards, Schreiner said. Also important is that it can be integrated easily into the company’s existing systems, and it provides precise data, can be well-monitored, and customized to PBS’ individual needs, he added.

“With the three-phase power measurement module, it is now much easier to monitor and control the actual energy consumption of complex production systems. The measurement modules provide voltage and current values for each of the three phases, as well as data about the blind function, output, and effective power,” Schreiner said.

Part of Environmental Operations

The energy reduction initiative fits well into the ISO 14001-certified manufacturer’s environmental policies. PBS Powder Coating’s other sustainability initiatives include a 1.2-MW photovoltaic system (see Figure 2), rainwater harvesting, the use of environmentally friendly chromate-free pretreatment, and a 2.5-MW biomass heating system, which is fueled with a regenerative fuel–wood chips.

Figure 2: PBS Powder Coating’s 1.2 MW large photovoltaic and energy management system are part of a comprehensive sustainability program.

“This will enable us to reduce our current oil consumption of about 1 million liters per year, thus helping to protect the environment by another 3,000 tons of CO_2,” Schreiner said. The wood chip demand of about 4,000 tons per year is locally sourced from the region. “This makes us much less dependent on the development of the oil and gas market.”

“The increasing development of renewable energy sources is an important contribution of our corporate policy. As a successful company, we assume this area of responsibility and help to accelerate this positive development,” Schreiner said. “Clean energy and energy management stabilize costs, safeguard jobs, and protect the environment.”

By consistently sustainable, environmentally oriented company policies, PBS Schreiner has set industry standards, according to the company.

Photos courtesy of PBS Powder Coating.

PBS Powder Coating, 36323 Grenbenau, Germany, 49 (6646) 9600 0, info@pbs-schreiner.de