BSH Hausgeräte GmbH is the largest manufacturer of home appliances in Europe, producing in over 40 factories in Europe, the United States, Latin America and Asia – from ovens, through dish-washers, washing machines, refrigerators and freezers, to vacuum cleaners, coffee machines, hot water appliances, irons or hair dryers. Sustainable management of resources is a firmly established element of this traditional company’s strategy – regarding both the appliances produced and the company’s own energy consumption. Within the scope of a group-wide project, energy consumption is supposed to be significantly reduced again – by means that include the introduction of systematic power monitoring in all production facilities.
The optimization of existing systems, plants and machinery requires precise detection and analysis of the relevant consumption data, as can only be accomplished by systematic power monitoring. BSH began this process in its refrigerator factory in Giengen: In a factory, now in operation for decades, state-of-the-art production methods are used to manufacture refrigerators and freezers for the European market. There are new and older systems in the mix, the maintenance is good and thus the framework conditions are typical for industrial production operations. The initial focus in power monitoring was on electricity. Not least due to financial considerations, as given the higher annual electricity costs, any savings in this category have an extremely rapid impact. Since mid-2015, there has been a successive worldwide roll-out in all BSH plants.
Software-based analysis of power dataIn terms of technical specifications, the company opted for the communication-capable 7KM PAC measuring devices from the Sentron portfolio, along with the corresponding powermanager software. Together with the measuring devices, the software creates a cohesive system, monitoring and archiving electrical parameters like voltage, current, power, energy values, and frequencies – right down to the system level. That is why over 200 measuring devices are used in the Giengen BSH plant: 7KM PAC 3200 standard models for medium and low-voltage capture and particularly powerful network-capable 7KM PAC 4200 models. The software can also handle other data sources, such as compressed-air meters, water meters, along with additional sensors for natural gas, helium, oxygen and nitrogen.
For example, this enables load profiles of different production lines to be compared with one another. Faults in the plants also become transparent, enabling them to be solved quickly and effectively. What’s more, BSH can more easily plan and track any optimizations. Not least, the software is flexible and individually configurable. The resource consumption can be directly and precisely attributed to individual machines or the entire value streams. Measures for improvements, e.g. by means of temporary disconnection or streamlined running of systems, are directly reflected in the bottom line of the respective production unit. The software and the 7KM PAC measuring devices are easy to install and use. The measuring points can be directly integrated via the existing IT infrastructure (LAN).