Specialists in plastics and tool technology
Whether for conveying plastic granulate, cooling tools, driving pneumatic systems, or controlling machines, compressed air is indispensable in the plastics industry. The requirements are high. Constant availability, optimal quality, and maximum energy efficiency are crucial for stable processes and cost-effective production.
FILCOM GmbH offers a comprehensive portfolio of reliable, energy-efficient KAESER compressors that are precisely tailored to the specific applications in plastics processing. Thanks to intelligent controls, modern drying technologies, and efficient filtration, customers receive a reliable compressed air supply with minimal operating costs and maximum system availability. An important contribution to greater sustainability, process reliability, and productivity in the plastics industry.
Gebr. Schwarz GmbH
Gebr. Schwarz GmbH in Rottweil-Neukirch is a state-of-the-art technology company specializing in plastics and tool technology. Founded in 1966, the company now employs around 200 people, providing precise, sophisticated, and innovative plastics solutions both nationally and internationally. The company's philosophy of producing innovative, complete plastic solutions tailored to individual needs is made possible by the involvement of all partners involved in the process. Gebr. Schwarz develops innovative plastic solutions for the fields of measurement and electrical engineering, sensor technology, healthcare, environmental and energy technology, and the automotive sector. The foundation for this is the company's methodological expertise, long-standing plastics know-how, quality systems, and state-of-the-art IT systems.
Challenge
The company uses air compressors in the production of complete plastics solutions. Compressed air is used here as process air for operating robot, assembly, and measuring systems. At maximum availability, approximately 2,053,000 m³ of compressed air are generated and delivered in the correct quality. This places high demands on the compressed air and its treatment within the company.
In order to make production processes even more efficient, a future-proof and efficient compressed air supply is essential. The company is aware of its responsibility towards future generations and the environment. Therefore, sustainable investments are being made at the site to optimize the plant and use the necessary energy as efficiently as possible. The focus here is also on recovering waste heat for heating purposes.
Solution statement
- In order to sustainably reduce energy consumption, the pressure level was reduced by over 1 bar.
- The combined effect of all measures resulting from the analysis was implemented to achieve a particularly high level of sustainability. The barely adequate compressors in the compressed air station were also replaced with highly efficient compressors with minimal redundancy.
- The KAESER ASD series compressors consistently implement these customer requirements in operational practice. They consume energy efficiently, are quiet, require little maintenance, operate reliably, and deliver even better compressed air quality.
- The KAESER air receiver fulfills important functions as a storage and buffer medium in the compressed air station. By reducing the overall pressure level, it significantly balances the usable buffer volume and thus ensures minimal compressor load changes.
Customer solution
- Through short response times, FILCOM guarantees maximum reliability for the customer. The sustainability of this partnership concept conserves resources and supports the redundancy concept at Gebr. Schwarz.
- As a user, Gebr. Schwarz GmbH expects high efficiency and reliability from its compressed air supply.
- By using a heat recovery system, energy already paid for can be used again for heating purposes.
- An insulated heating line ensured maximum energy savings. The equivalent of 6,600 liters of heating oil and €10,000 in heating oil costs were saved, and CO2 emissions were reduced by 38 tons per year. Electricity consumption was reduced by 26%.