Energy inspection for air technology systems
Many manufacturing plants are aware of the energy consumption of their ventilation systems – but not the reasons behind it or the potential for optimisation. An energy audit reveals where an existing system is consuming more energy than necessary and which measures are cost-effective.
# On-site inspection plus data-based evaluation
# Result: prioritized action plan with economic evaluation
Why are
maintenance and consumption meters
not enough?
Regular maintenance ensures that components are working properly. An energy meter shows how much energy the system is using. Neither of these answers the crucial question: does the process actually need this energy?
Maintenance checks defined components against their target state. Whether this target state is still appropriate for current production remains an open question. The meter provides a total figure, but no explanation of the cause. This is precisely where the energy audit comes in. It assesses plant design, operating mode and control systems in conjunction with the actual process. In this way, a consumption figure is transformed into a comprehensible analysis of the causes – complete with specific levers for action.
What is an
energy inspection?
The energy inspection is a systematic analysis of the energy flows of existing air technology systems (workplace, machine extraction, process air technology, etc.) as well as room air and energy technology (hall air cleaning, ventilation, hall heating and cooling, etc.). The goal is to identify and economically evaluate energy-saving potentials – without compromising production safety or required air quality.
Kappa considers both the overall system and individual components.
The study will examine, amongst other things:
- System design compared to current demand
- Operating modes, control strategies, and load and demand management
- Fans and drive technology
- Air guidance, filter cleaning, and other components
- Energy consumption of the overall system and individual components
- Potentials for energy recovery
Measure on site, analyse using data
The analysis combines on-site inspection with the evaluation of existing operational data. Load profiles and operating conditions reveal when the plant is operating at a higher capacity than necessary. Where possible, the Kappa service team implements initial measures straight away, for example by adjusting settings or control parameters. Depending on the load profile and operating hours, such measures can reduce energy consumption compared with current operations from that point onwards.
How does the energy inspection work?
Initial conversation
You describe the system, production, and goal. Kappa clarifies which data is available and what scope is reasonable
On-site inspection:
The Kappa service team takes the system into operation and checks components, controls, and operating conditions.
Data evaluation: Kappa evaluates operating data, load profiles, and measurement results and assesses each measure economically.
Action plan:
Action plan: You will receive a list of prioritised optimisation measures, including potential savings, investment costs, payback period and total cost of ownership (TCO).
Implementation and further development:
Implementation and further development: Kappa will implement the measures on request. Kappa digital RetroFIT also enables existing systems to be digitised in stages and ensures that energy consumption remains transparent in the long term.
What are the benefits of an energy audit?
The inspection turns a black box into an assessable system. It provides answers for maintenance and a decision-making basis for plant management and controlling.
Transparency about real operating conditions
You can see which components require how much energy and in which operating conditions losses occur. Maintenance receives clearly identified weaknesses instead of assumptions.
Lower energy and operating costs without interfering with production
Adjusted volume flows, operating times, and control parameters reduce electrical power consumption in partial load operation. This utilizes the potentials of the existing system before new technology becomes necessary. The amount of savings depends on load profile, operating hours, and system condition and is determined on a project-specific basis.
Plan investments based on solid foundations
The action plan shows savings potential, investment costs, and payback time for each measure. If necessary, Kappa evaluates the measures according to DIN EN 17463 (VALERI). The method not only considers the simple payback period but also calculates the capital value taking into account interest, price increases, and residual values over the entire service life. This allows optimization, retrofit, and replacement investments to be compared on the same basis.
Extend the use of existing investments
Instead of prematurely replacing a system, it is adapted to current needs. This protects the existing investment and creates a robust basis for monitoring and documenting energy metrics.
Interesting facts
FAQ
The energy inspection is a systematic analysis of existing extraction, ventilation, and air purification systems. It combines on-site inspection with the evaluation of operational data. The goal is to identify causes of unnecessary energy demand and to economically assess optimization measures. The result is a prioritized action plan with savings potential, investment costs, and payback period.
Maintenance checks whether components meet their defined target condition and addresses identifiable deficiencies. The energy inspection asks whether this target condition still fits the current production needs. It evaluates design, control, and operation in conjunction with the process and shows where the system requires more energy than necessary.
This depends on system design, load profile, operating hours, control strategy, and the condition of the components. Therefore, blanket percentage values are not reliable. The inspection determines the savings potential on a project-specific basis. In a practical example from a vehicle manufacturer, a potential of around 307,000 kWh per year was identified compared to the existing operation.
The inspection is designed to ensure that production safety and required air quality are not compromised. The system will be operated in real conditions because this operational behavior is what needs to be evaluated.
Existing system data, operating times, and consumption values are helpful, as far as available. If data is missing, Kappa will capture the relevant operating conditions during the inspection. On your side, it is mainly necessary to have a contact person who knows the system and production processes, and access to the system.
It is suitable for existing air technology systems in exhaust technology and indoor air technology, such as workplace and machine extraction systems or central hall air cleaning systems. It is particularly relevant for systems that have grown over the years, been expanded multiple times, or adapted to changed production conditions.
Let's talk about your project
Please share your requirements and goals with us. Our specialists are happy to support you from the initial consultation to implementation.
Kappa Filter Systems GmbH
AT-4407 Steyr-Gleink, Im Stadtgut A1
0043 7252 21 111
DE-40549 Düsseldorf, Wiesenstraße 21
0049 211 506 6978 0
office@kappa-fs.com
www.kappa-fs.com