New nkt cables factory to reduce energy consumption dramatically
Energy savings and CO2 initiatives can have far-reaching effects on people, processes, flows, logistics and buildings. At its new factory in Cologne, nkt cables will reduce overall energy used for heating by around 80%. By itself this will mean a saving of 300,000 EUR annually.
nkt cables in Cologne is well advanced with the building of a brand-new factory for the manufacture of cables: medium and high voltage cables, submarine cables and intelligent overhead lines, OPGW and OPPC, and superconducting cables. The new facility is located on the Rhine, so that the large, heavy cables can be literally ‘shipped’ directly from the factory. This in itself is an environmental saving. But it’s far from being the only one.
“With the new factory, which is being built to our own environmental requirements, we will reduce total energy consumption for heating purposes by around 80% annually. In terms of CO2 emission this corresponds to a saving of 2,700 tonnes and in monetary terms a saving of around 300,000 EUR annually. We will not only be more efficient environmentally, we will also be more efficient as a business,” says Anders Moestrup Rasmussen, Operations Director at nkt cables, Germany.
“The existing factory consists of a large number of buildings up to 130 years old, and although a number of energy economies have been introduced it would be an exaggeration to say that the premises are energy-efficient by today’s standards. When production is spread over several buildings there are a large number of entrances to be opened and closed. This not only results in heat loss, it also slows down
production because intermediate transport movements are required in which the heavy cables have to be physically relocated during the manufacturing process,” continues Anders Moestrup Rasmussen.
Optimized production and energy consumption
The new facility offers a single production hall, which for nkt cables will mean reduced heat loss due to fewer entrances, reduced waiting time, and greatly improved production flow.
”In summertime the offices will be cooled by means of water pipes installed in the floors. At night, when the outside temperature falls, water will be piped through our condensate coolers, thereby cooling the floor itself. This will provide a pleasantly cool building ready for our staff in the morning. In winter, the pipes will carry hot water produced by surplus heat from the production equipment. In combination with the latest building insulation standard we have created a very energy-efficient office environment that avoids air conditioning and its associated drawbacks in the form of high energy consumption and particularly draught,” explains Anders Moestrup Rasmussen.
All surplus heat from equipment cooling water will be used to heat the factory floors, for product tempering processes, and for heating water for the kitchen and changing rooms. In parts of the factory, space heating will be supplemented by radiant gas heating. This heating is very precise, being directly targetable.
Good investment
”Energy efficiency has been a focal consideration in our construction project since day 1. Without assistance and collaboration between our project management and an outside expert we would never have stood a chance of realizing the highly complex task of creating an optimal energy supply and consumption system for our offices and factory. It has without doubt been a good investment both environmentally and financially.” declares Anders Moestrup Rasmussen.
”Not only will we reduce CO2 emission but we will also reduce our expenditure. We have implemented a process optimization that will deliver an integrated flow throughout the value chain, benefiting our clients and thus also ourselves. The new factory will support not only the environment but also our production flow and our existing and future management culture,” says Anders Moestrup Rasmussen.
”The first production phase at the new factory has now begun, and relocation from the existing factory is expected to be completed by the end of 2010. The new facility has been named 'f2c', standing for Flow to Customer. This reflects the philosophy that underlies the building’s planning, construction and future operation,” says Anders Moestrup Rasmussen.
Climate change
nkt cables is part of the global industrial conglomerate NKT. “At NKT we wish to support the development towards more environmentally sustainable business operation. Industry and production have an important part to play in the effort to control carbon emission, and it is NKT’s ambition to reduce the Group’s carbon dioxide emission relative to output by at least 12% in the period 2009-2011”, says CEO Thomas Hofman-Bang, NKT Holding.
The NKT Group also includes Nilfisk-Advance, one of the world’s largest manufacturers and suppliers of cleaning equipment, the Photonics Group that comprises three companies, all players in the optical industry and NKT Flexibles, a supplier in the offshore sector and of which NKT owns 51%.