Galvanised plate drying refurbishment pays back in only 20 months
The Belgian company Niko NV delivers more than 5000 products and solutions for switching materials, door communication systems, lighting control and home automation systems and has branch offices in Europe and a wide network of agent and distributors.
At Niko’s manufacturing plant in Belgium attention is paid to control and minimize the impact on our environment and actions are taken to e.g. reduce energy consumption. Munters desiccant dehumidifier type MDS1500 was installed in the 1990's to provide dry air to a drying process of galvanized plates after undergoing a process in a zink bath. The MDS unit has an airflow of 15,000m³ and is running continuously 12 hours a day, 5 days a week.
Refurbishment paying off
A recent performance check-up of the MDS unit concluded that a refurbishment of the unit would lead to improved dehumidification capacity and significant energy savings. Munters Belgium presented a solution for a thorough refurbishment of the MDS unit which is now implemented. As the capacity of the rotor (desiccant drying wheel) had dropped significantly over the many years of daily use, the drying time of the galvanized plates was no longer optimal. By replacing the rotor the drying time of the plates has been significantly shortened. The gain of improved production capacity is estimated by the customer to amount to € 25,000/year.
Range of energy saving measures implemented
Niko NV has access to 50°C warm water from cooling compressors, water that was so far treated as waste water. The MDS dehumidifier is now equipped with a coil for pre-heating of the air stream used for regeneration of the desiccant rotor. Utilizing the warm waste water for the heating coil will ensure a reduction in cost for regeneration of approx. € 10,400/yr. An internal heat recovery purge sector (Energy Recovery Purge) has been added and works by recirculating the air into the regeneration cycle after the heater. This energy saving feature will add another saving of € 2,200/year.
Stable future operation secured
The refurbishment also included a complete update of vital components, such as fan bearings, drive motor, belts and sealings, ensuring that the operation will remain reliable and trouble free years ahead. Continuously working on optimising both dehumidification capacity and energy efficiency, Munters is also very much focused on using the best possible control systems for easy controlling and monitoring of the dehumidifiers and other air treatment solutions. The MDS at Niko’s manufacturing facility has now been updated to a new Climatix control that integrates with the BMS (Building Management System). Furthermore the electrical cabinet was updated to include modern components.
ROI at only 20 months
The improved energy efficiency and higher rotor capacity will ensure annual savings that grants Niko a ROI (Return of Investment) of only 20 months. On top of this short ROI, Niko also benefits from the significantly higher production capacity – an amount NOT included in the calculation of the ROI. Following the refurbishment the MDS unit’s vital parts are all be new and updated and the unit is expected to deliver the required climate conditions in the production area for many years ahead.
Munters Belgium is a trusted service partner with Niko and during annual service visits, the performance and operation of the MDS unit will be closely monitored. Regular replacement of consumable parts, such as filters, will be taken care of by Munters’ service engineers performing the scheduled maintenance on site.
For further information on Munters' Service and energy optimisation options, please visit www.munters.com/service.