Dr. Volker Bauer, managing director of LTG AEROB Filtration Solutions GmbH, has set his mind not only to creating product innovations, but also to optimizing existing systems and processes. Especially with an eye on customers’ continuously rising demands regarding the lifespan of their systems and reduced energy consumption, the holder of a doctoral degree in process engineering can offer solutions.
But he is not the only one representing the know-how of the WEIS INDUSTRIES Group in the sector of process optimization. Numerous previously realized projects for a variety of customers demonstrate the great competence that the company group can offer in this field. The WEISZEIT editors interviewed Dr. Volker Bauer as a representative of the group, asking him about the potentials and possibilities of this method.

WZ ed.: What does process or energy optimization mean, and what are the requirements to perform it?
V. Bauer: We all should constantly optimize our processes with regard to safety and profitability. The potentials for optimization vary strongly depending on the process at hand and must be determined individually. A high degree of engineering competence and a wealth of experience are necessary requirements to do this. Both of these qualities are abundantly present in the WEIS INDUSTRIES Group.

WZ ed.: How do you proceed when you are at the customer’s site?
V. Bauer: Basically, the following approach has turned out to be very successful: First, we conduct an analysis together with the customer. In the course of this analysis, we must answer the relevant questions: Does the process do its job, and what are the alternatives that could do a better job? Then, we take a look at the components. Here, too, we ask whether they are up to their task and whether they are procedurally and constructively sound. We are looking at ways to optimize them with regard to safety and profitability. After that, we analyze the control system and the working process and examine whether the components are properly synchronized. Finally, we decide whether they can be optimized through maintenance or modernization.

WZ ed.: What are the cost-saving potentials and when are these investments amortized?
V. Bauer: There’s no easy answer for that, really. Cost-saving potentials and amortization periods strongly depend on what optimizations are done at what stage in the above-mentioned process. On average, we expect amortization periods to be anywhere between a couple of months and two years. In principle, optimization is possible for every process – and it should be performed iat regular intervals, or at the latest once the process parameters change.

WZ ed.: Can you give us some reallife examples of successful optimizations?
V. Bauer: For example, in the conditioning of a production hall in the textile industry, we succeeded in reducing energy consumption by about 70 percent by switching from traditional air conditioning (humidification and cooling) to mixed conditioning with direct evaporative cooling. Air volumes were reduced by 50 percent. In another case, by applying components that were specifically adapted to the process, we reduced these components’ energy consumption by more than 40 percent while also increasing availability.

This goes to show that process optimization not only creates advantages in terms of safety and profitability, but also can increase a system’s availability and lifespan and significantly reduce maintenance requirements. We have successfully completed numerous projects in cooperation with our customers and will continue to provide our expertise in the field of process optimization. The demand shows that this service is becoming more and more important in the face of rising material and energy costs.