Henkel Central Eastern Europe (CEE) in Vienna has saved energy at its modern production facility for laundry detergents by establishing three air networks fed by Atlas Copco compressors with different operating pressures for various applications throughout its plant premises.
Compressors feeding air into three different air networks
Henkel CEE, based in Vienna, Austria, is one of the most successful branded goods companies in Eastern Europe. Vienna is also home to one of the most modern production facilities for laundry detergents, with a focus on the production of liquid detergents. Approximately 230,000 tons of detergent are produced each year, which means a correspondingly high demand for compressed air for the entire Vienna site. The production facility is operated with many oil-injected screw compressors, such as the GA 160 with variable speed drive (VSD), as well as oil-free low-pressure Class 0 ZA/ZR screw compressors.
Throughout the facility, the demand for compressed air varies depending on the application. For loading and unloading tank trucks, a low-pressure network of 3 bar is required. The control air to drive the units on the plant premises requires 7 bar working pressure, and an operating pressure of 11 bar is used for the production area of the stretch blow molding plants, where PET bottles are made. Because of this, Henkel decided to set up three compressed air networks with different operating pressures to achieve cost efficiencies and energy savings.
Class 0 certification means zero risk of oil contamination
“Operating the entire network using 11 bar would mean wasted energy because each 1-bar reduction leads to an energy saving of 7 percent,” explains Di Hannes Dengg, technical director of Henkel CEE at the Vienna site.
Atlas Copco’s innovative designs for both the GA and ZA/ZR compressor lines feature a variable speed drive, which further reduces energy costs by up to 35 percent on average by automatically adjusting the air supply to meet demand. At the Vienna plant, the drive outputs vary between 75 and 315 kW respectively. In addition, when speed-controlled compressors are used in the winter months, the waste heat from the air-cooled compressors is used to heat the high rack, a testament to Henkel’s commitment to sustainability.
Cold-air absorption dryers and compressed air filters ensure clean and safe production. This is critical in the production of laundry detergents, and the Class 0 certification of the ZA/ZR compressors means zero risk of oil contamination to Henkel’s products.
Global players are preferred partners
Production is not restricted to the Vienna site. Henkel also has plants in Central and Eastern European countries, including Turkey, Serbia, Hungary, and Poland.
“With production plants in different countries, it is important to work with a reliable partner who delivers reliable supplies and supports us with overall project development. Atlas Copco is a global player in the field of compressed air technology and guarantees consultancy and on-site service with its worldwide presence,” explains Christian Weiser, head of liquid production at Henkel CEE.
About Henkel CEE
Henkel CEE, based in Vienna, Austria, is one of the most successful branded goods companies in Eastern Europe. Henkel CEE is the market leader for hair care products, adhesives and surface technologies in the region. In detergents and household cleaners, Henkel CEE holds a leading position. The company operates in 32 countries in Central and Eastern Europe, as well as in Central Asia. In 2012 the company had approximately 9,000 employees and recorded sales of EUR 3.024 billion.
Atlas Copco’s Compressor Technique business area provides industrial compressors, gas and process compressors and expanders, air and gas treatment equipment and air management systems. It has a global service network and offers specialty rental services. Compressor Technique innovates for sustainable productivity in the manufacturing, oil and gas, and process industries. Principal product development and manufacturing units are located in Belgium, Germany, the United States, China and India.
Atlas Copco is an industrial group with world-leading positions in compressors, expanders and air treatment systems, construction and mining equipment, power tools and assembly systems. With innovative products and services, Atlas Copco delivers solutions for sustainable productivity. The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2012, Atlas Copco had 39 800 employees and revenues of BSEK 90.5 (BEUR 10.5).