Cost, time, quality and sustainability: the four central cornerstones in projects form the “squaring of the triangle”, which will take on increasing importance in the future. Especially in production projects, this holistic view is increasingly being driven forward. Business Unit Manager Oliver Hardt and Martin Hadamla from Technology Management at MVI PROPLANT Nord integrate sustainable practices and technologies into existing processes and thus develop new innovative approaches.
Why sustainability is relevant
The Zukunftsinstitut describes the megatrend neo-ecology as a social movement and important economic factor. Sustainability influences corporate sectors and is increasingly supported by politics. Oliver Hardt emphasises the responsibility of the manufacturing industry to create a sustainable world for current and future generations, with legislators currently providing strong support.
With the introduction of energy and environmental management systems (ISO 50 001 & 14 0001), the consideration of environmentally critical resources in production in particular is taking on a new significance that goes beyond pure monetary value. Experienced technology expert Martin Hadamla adds: “This view is further flanked by extended measures through legislation such as CO2 certificate trading or tax incentives through audits according to ISO 50 001 or ISO 14 001.”
Customers are responding to this. “OEMs have created entire sustainability departments that develop overall strategies. Tier 1 suppliers also have to deal with sustainable production, both because of the cost pressure on products and because of the supply chain law on the CO2 footprint of products. Their productions have to become more efficient and sustainable to remain competitive,” Oliver Hardt knows from conversations with customers.
Sustainability at MVI PROPLANT
The topic of sustainable production management is now more than ever an important guideline and goal for companies. Over the past ten years, MVI PROPLANT has already examined all the requirements for efficiency and sustainability in many production projects and, in most cases, implemented them. “We have already realised numerous plants and production facilities in accordance with sustainability requirements. Together, MVI PROPLANT North and South are experts in this field after so many years “, says Oliver Hardt.
Consultancy, planning and implementation services as well as follow-up support for customers are provided in full together with MVI PROPLANT’s IT and logistics. Individual commissioning is also possible. Martin Hadamla adds: “We always focus on the overall process in a production and localise potential for more sustainable production at an early stage. Long-term support along the production process is the goal.”
What is the potential of sustainable production management?
In order to comply with sustainability regulations, there are often bureaucratic hurdles at the beginning. Our service includes accompanying clients through this process in order to be able to submit the funding applications. What should not be underestimated, however, is the company value, which definitely increases. “Cost reductions are achieved primarily through energy and material savings and secondarily through government grants of up to 40% of eligible investment costs.”
Other benefits include increased productivity through consistent application of management systems, creation of legal certainty and adequate risk management to safeguard energy and resources. The latter point is particularly important when ad hoc decisions have to be made in the event of material shortages or supply fluctuations, such as supply chain problems.
“Sustainable production management can significantly optimise operating procedures and decision-making processes for customers through holistic networking and consideration”. Future production processes will not only focus on efficiency, but will also include environmentally relevant elements. Sustainability in general is therefore becoming increasingly important for all companies, including MVI, in order to remain a competent partner for customers and an attractive employer for applicants.
Two MVI PROPLANT example projects for sustainable production planning.
They show how much savings potential is possible for customers:
- Modernisation of an aluminium smelter:
As part of the project, two ageing melting furnace lines with a capacity of approx. 3 t/h of melt were replaced by “state of the art” equipment. By optimising the temperature control within the furnaces, it was possible to significantly increase the preheating effect, so that the primary energy is used more effectively for melting. Furthermore, part of the “residual energy”, which was threatening to dissipate in the exhaust gas flow of the plant, was decoupled and regeneratively fed back into the process to increase energy efficiency.
Due to a process change, the process step “intermediate heating for transport” could be omitted and saves considerable energy and labour. Furthermore, the filling of the melt into a transport ladle was optimised in the same way as the pouring of a wheat beer. The melt now does not simply fall to the bottom of the transport ladle and swirl, but runs down the ladle wall and gently nestles against the bottom of the ladle (wheat beer drinkers know the difference). These and other optimisations have realised a product cost saving of 38 % as well as a reduction in CO2 emissions of 65 % compared to the old system.
- Energy management: electricity efficiency in production
MVI PROPLANT was to create a production data acquisition (PDA) system for the plant. In addition, a “map for determining the consumption drivers (electricity)” was compiled for the plant. An analysis and allocation of power supply and control cabinets as well as further implemented optimisation measures achieved an energy saving of 13% for the entire plant.
Sustainability in production is increasingly becoming the basis for sustainable companies. MVI PROPLANT develops innovative approaches and implements projects so that sustainable solutions not only save costs and resources, but also increase quality and set new standards.
