Energy-optimized germination process thanks to hx control.
The germination process is a highly energy-intensive production step for a Malthouse. Modern automation solutions offer unbeatable added value here, ensuring energy-optimized operation and thereby saving valuable energy. As part of a comprehensive modernization of the automation system—which was over 30 years old —we were commissioned by a well-known Bavarian Malthouse to replace the entire control system infrastructure and implement automated control systems.
Thanks to redundant servers, the replacement of the old S5 controllers with modern S7 controllers, and the use of electronic curve recording, we are not only increasing process reliability but also creating an optimal foundation for the integration of a key technology: hx control.
”"What used to require manual adjustments based on extensive experience is now 100 percent automated."
Peter StinglProjektleiter, planemos GmbH
The challenge: Reduce cooling capacity to a minimum
Since plants are operated over very long periods of time, it makes sense to continuously optimize cooling capacity in malt production using automated control systems.
hx control is the solution
The hx control system calculates the optimal mix ratio of recirculated air and fresh air to ensure that cooling operates in a controlled manner while using a minimum of energy. This prevents energy-intensive condensation processes and reduces cooling energy consumption and harmful CO2 emissions by up to 30%.
Combined heat and power plant successfully connected
By connecting the two malthouses to a combined heat and power (CHP) plant, the excess waste heat generated during kilning can be put to good use. A control system we developed ensures minimal downtime. The process heat can now be fed back into the process via combined heat and power, measured, and optimized.
Hybrid onboarding during the pandemic. Not everyone can do it.
We are certain that 95% of our customers would not have accepted remote commissioning before the pandemic. COVID-19 required us to be as flexible as possible on this project. On-site appointments and site visits were kept to a minimum. Thanks to a well-coordinated team, most of the coordination took place primarily online.
Only the hardware was installed on-site by our team of electricians. The entire software setup, including all system tests, was successfully completed remotely within an extremely short time frame.
