Elegant design, efficient production

How do you ensure that a product is manufactured in a resource-efficient manner? Bette uses a comprehensive energy management system that allows for detailed monitoring of energy consumption in production.
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The challenge

Transparency meets efficiency

Elegance and lightness: Bette products create an inspiring space in bathroom design. The high-quality bathroom components not only feature an attractive and elegant design but are also produced with the highest quality and sustainability in mind.

Unique technology allows for the creation of elegant shapes.

Many of Bette’s products are essentially one-off designs. “Our automated serial production line can handle more than 600 different colors and numerous additional features,” says Mark Becker, energy manager at Bette. “If you take all the possible combinations together, we have several million products in our portfolio, which, thanks to our state-of-the-art production systems, we are able to manufacture and deliver within a very short time.” This wide product range poses a number of challenges – not only for automation technology. Monitoring and optimizing the use of resources, in particular compressed air for shaping, is a key factor in cost-effective production at Bette.

Bette GmbH & Co. KG

Premium steel alloys

Bette, a family-run company based in Delbrück, Germany, has been producing architectural bathroom components from steel-titanium alloys enameled with purely natural materials since 1952. A unique procedure enables Bette to produce a particularly low, uniform steel thickness. This in turn enables the company to create innovative shapes and designs that are also highly durable.

Individual shapes and completely new design solutions are both attractive and functional

Visitors can view some of the various design options in the Bette showroom in Delbrück and gather ideas for their bathrooms. Only a few of these individuals will be interested in the technology Bette adopted to produce the lightweight shapes and designs. “Our products are made from steel-titanium alloy enameled with purely natural materials – using a one-of-a-kind molding technique,” explains Mark Becker, energy manager at Bette. “Rather than stretching the steel, it pulls it smoothly into its final shape.” The basic form is then created by trimming according to the final dimensions and finishing the edges individually. In addition to design, at Bette the focus is also on sustainability. “Our products should be produced in both a high-quality and efficient manner – this has the personal attention of our managing director,” continues Becker.

Our products should be produced in both a high-quality and efficient manner – this has the personal attention of our managing director.
Mark Becker, Energy Manager, Bette GmbH & Co. KG
Solution

Seamless monitoring of energy flows

Over the years, Bette has invested heavily in efficient production. The core of energy management is an integrated solution that the company uses to monitor and evaluate its energy flows in detail – and that also offers the company a wide range of options for further optimizing its processes.

An integrated solution for monitoring energy flows creates transparency

During the implementation project, Bette modernized the machinery and systems for producing and distributing compressed air, ensuring that highly efficient components were used. Suppliers were required to use motors of energy efficiency class IE3, in accordance with IEC 60034-30, and machines that consume as little compressed air as possible. In addition, not only the new machinery and systems but also the existing ones were equipped with systems that record energy consumption. In addition to a large number of SENTRON PAC3200 power monitoring devices, SIMATIC ET 200SP AI Energy Meters are installed in the air compressors. The compressed air consumption in the individual departments is also recorded using SIMATIC ET 200SP systems. To configure the entire measuring system, Bette used SIMATIC Energy Suite, a tool that allows for easy integration of energy measuring points into the automation software. The user moves the corresponding block for an energy object to the configuration via drag and drop and then just needs to configure it. The data merge in two specially installed SIMATIC S7-1500 controllers, which record the consumption data for electrical energy during production and energy consumption for producing compressed air. From there, the data are then transmitted to the SIMATIC WinCC Professional SCADA system and SIMATIC Energy Manager PRO.

Benefits

Basis for efficiency

With the data from the energy management system, Bette is able not only to satisfy the requirements of the EN 16247 standard but also to better pursue and implement its own business objectives.

The systems complementeach other perfectly

Mark Becker can display the energy flows in both WinCC and Energy Manager PRO. “In SIMATIC WinCC we can see the energy flows together with other production information down to the second and therefore have a good overview of what is currently being consumed where,” he says. “The data can also be analyzed and evaluated in corresponding dashboards in the Energy Manager. This enables us to match consumption data to the departments and monitor and compare key figures – in short, everything we need for evaluating our energy efficiency.”

In order to assess our energy efficiency, we first need transparency. Our energy management system offers all the options we need.
Mark Becker, Energy Manager, Bette GmbH & Co. KG

Bette is currently working to integrate the remaining systems into the energy management system and in parallel to this is extending the data and consumption analysis options. An expansion to the system has already been planned: load management. At the moment, Bette is still working with a solution from an energy supplier but will assume this task itself in the future. “This system is currently working in a relatively rigid manner by switching units on and off. We are moving toward a modern system that definitely offers considerable savings possibilities,” adds Mark Becker. “And integrated energy management provides the basis for these savings. The data from the machines and the systems are networked, we know what is consumed where and why, and we can switch units on and off in a purposeful manner.”