German precision tool manufacturer: Integrated efficiency

The German precision tool manufacturer Mader is committed to environmentally friendly and sustainable operation. Ensuring greater energy efficiency is therefore crucial to the company – and thanks to the power monitoring system from Siemens can now be achieved. 

The precision tools made by Mader GmbH & Co. KG, based in the Bavarian Allgäu, have been renowned for their high quality for over four decades. Managing director Gert Mader and his 35 employees are therefore pursuing more than just the ambitious goal of being the most technically advanced company in the area, they also want to operate sustainably. With the “Mader eco concept” – part of the company philosophy – the manufacturer has committed itself to sustainable, environmentally friendly operation. 


The company’s operational building with 2,300 m2 of floor space is located in Pfaffenhausen near Mindelheim, Bavaria. Right from the start the buildings and production systems were designed sustainably and equipped with low-energy heating and lighting control with presence detectors. But that was not enough for Gert Mader because the annual electricity consumption in the company was still around 300,000 kW. It was therefore clear from the outset that the greatest energy potential lay in the energy-intensive production. To exploit this potential, Mader worked with the engineering company actensys, which specializes in innovative, sustainable energy solutions, to introduce a power monitoring system. 

Transparency with powermanager

The powermanager software and the 7KM PAC measuring devices from the Sentron portfolio provide the technical basis for the reduction of energy consumption. The software monitors and archives electrical parameters such as voltages, currents, power, energy levels, and frequencies with the help of the measuring devices. Through the transparent analysis of energy flows, imminent peak loads can be identified early and thus avoided. Switching on the ventilation system can be delayed when many machines are running at the same time, for example. Furthermore, data transparency enables individual loads to be analyzed specifically for savings potential. In the future, Mader will also be able to detect faults in the machines early on.

Complete solution in a cabinet

All measuring devices, as well as the PC running powermanager, are compactly and clearly incorporated into a single Alpha distribution board from Siemens. This allowed the entire solution to be completely installed and tested at actensys in advance and put into operation quickly and easily on-site. In addition to the components for the power monitoring system, the cabinet contains all the necessary protective devices. This comprehensive protection solution is particularly important for the precision tool manufacturer because individual machines are running around the clock in unmanned automatic mode in some cases.


Picture credits: Siemens AG/W. Geyer


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