Up to 30% less energy consumption through intelligent retrofitting
An existing central exhaust system was digitized and energetically optimized without production interruption. By combining energy-efficient filter elements, demand-based speed control, and real-time monitoring, energy consumption was reduced by up to 30%.
The challenge
In many production facilities, centralised exhaust air systems operate reliably for years, but with constant operating parameters. This was also the case at a company in the food and agricultural sector: the existing bag filter system ran continuously at a high fan speed – regardless of the actual air demand. This resulted in avoidable energy costs and unnecessarily high electricity consumption.
At the same time, there was a lack of continuous recording of relevant operating data. Energy consumption, differential pressure, volumetric flow, or filter condition were not transparently monitorable. This resulted in a lack of a solid basis for reliable plant evaluation and predictive maintenance.
A solution was therefore sought that would meet three requirements simultaneously:
- Reduction of energy consumption
- Digitization and transparent monitoring of the existing system
- Retrofitting without extensive renovations or production downtime
The solution
Instead of completely replacing the existing filter system, it was specifically modernised using a Digital Retrofit™. The existing technology continued to be used and was supplemented with digital measurement, monitoring and control components.
A plug-and-play system continuously captures, among other things:
- Differential pressure
- Volumetric flow and air velocity
- Filter conditions and operating hours
- Energy consumption
The data is provided in real-time via Kappa Scopic®and enables location-independent monitoring. Operational deviations can be detected early, and the condition of the system can be tracked at any time.
Additionally, the existing filter hoses were replaced with energy-optimized Waveline® filter elements replaced and integrated a demand-based speed control. The fan automatically adjusts its performance to the actual air demand instead of running continuously at high speed.
The modernization was implemented without any modifications to the existing control cabinet and without interrupting production operations.
The result
The Digital Retrofit™ modernized the existing exhaust system both energetically and digitally. Intelligent control, energy-optimized filter elements, and real-time monitoring provide more transparency, energy efficiency, and maintainability.
- Up to 30% less power consumption
- Complete retrofitting of the existing exhaust system
- Real-time capture of relevant operational data
- No production interruption
- No control cabinet modification required
- REST API for connecting existing systems
- Warning and alarm functions for predictive maintenance
Project conclusion
The project shows that existing exhaust and filter systems do not necessarily need to be replaced to improve energy efficiency and digitalization. Through the targeted Digital Retrofit™, the existing bag filter system was enhanced with modern sensors, real-time monitoring, and intelligent control. Energy-optimized filter elements reduced power consumption by up to 30%.
For operators of industrial exhaust systems, the concept offers an economically attractive way to continue using existing infrastructure while also improving transparency, energy efficiency, and system availability.