SPIE Energy Solutions GmbH

Improved energy efficiency not only reduces_{CO2 emissions} and relieves the burden on the environment, but also lowers operating costs. For us, increased energy efficiency also means reducing risks and achieving security of supply. Because only through the interaction of all parameters can we achieve sustainable solutions for our customers.

In doing so, we have further developed traditional contracting. For us, it is not enough to offer customized contracting solutions.
We enter into energy-saving partnerships with our customers and allow ourselves to be measured by our results: Because we contractually guarantee savings.
Of course, we also offer contract models for pure media supply or as part of full-service models.

In order to protect the climate and support the energy transition, we are also active in the field of electromobility.

We proactively develop and implement solutions for improved energy efficiency for our customers - because we are aware of our social and ecological responsibility.

We are active in the following areas:

• ENERGY MANAGEMENT
• ENERGY INFRASTRUCTURES
• MEDIA SUPPLY AND ENERGY DELIVERY
• ENERGY-EFFICIENT LIGHTING
• CONSULTING

Takeda Pharma GmbH in Singen is part of the globally active Takeda Pharmaceutical Company Ltd. group. With around 600 employees, Singen is one of the major sites with the production and administration divisions.

At the Singen plant, Takeda manufactures pharmaceuticals in various dosage forms. The main focus is the production of the drug Pantoprazole as a freeze-dried powder, which is filled into small glass vials. These very durable vials are then filled with a solution and administered intravenously to the patient during treatment in the clinic or doctor's surgery.

Takeda in Singen also produces a nasal spray for hay fever allergy sufferers as well as various ointments and suppositories.

For this site, SPIE Energy Solutions GmbH was commissioned to examine the energy infrastructure holistically for possible cost and CO2 savings. The result of this analysis was a package of measures individually tailored to Takeda's needs, which could open up enormous savings potential. Convinced by the results and the approach, Takeda commissioned the energy service provider SPIE to implement the new energy supply concept.

Requirements

The pharmaceutical industry is increasingly confronted with regulatory requirements as well as new requirements for development and production facilities. The implementation of these regulations in a pharmaceutical company requires high investments under increasing cost pressure.

The aim and aspiration of the project partners was to combine resource and energy efficiency with economic success. Takeda attached great importance to a holistic view of the energy infrastructure. The necessary investment costs were to be fully refinanced from the savings.

It was particularly important to Takeda that the implementation should be as interface-free as possible without affecting production and that both the investment costs and the savings could be planned.

Results

With the implemented energy supply concept, Takeda will save at least 1.1 million euros and around 4,350 tons of CO2 annually in the future. The core of the optimization is a combined heat, power and cooling system (CHP) for the combined generation of electricity, heat, steam and cooling. In future, Takeda will produce around 50% of the electricity required at the site itself. In summer, the heat from the combined heat and power plant (CHP) is converted into cold using an absorption chiller, thus helping to cool the clean rooms. In addition, a new cooling center with two highly efficient chillers was built. Three new cooling towers ensure sufficient cold water at all times.

Another component of the package of measures is the conversion of parts of the lighting to energy-saving LED technology. The package of measures is rounded off by a new building management system and an intelligent energy data recording system.

As general contractor, SPIE was responsible for the design, planning and turnkey implementation of the new energy supply concept at a fixed all-inclusive price.

As part of the operational management, SPIE guarantees that the savings will be achieved over the ten-year term of the contract.

Services provided by SPIE Energy Solutions

• Design, planning and implementation of a new energy supply concept
• Construction of a CHP plant for the combined generation of electricity, heat, steam and cooling
• Securing the forecast annual cost reduction of over 1.1 million euros through a savings guarantee
• Energy management (energy monitoring and controlling)
• Maintenance and servicing

Individual measures

• Installation of a combined heat, power, steam and cooling system for the production of electricity, heat, steam and cold water
• Construction of a CHP heating water line and hydraulic balancing of the heating water network to reduce the heating return and CHP inlet temperatures
• Installation of an air preheater for the steam boiler
• Installation of a new central cooling unit
• Implementation of an energy-saving LED lighting concept with 600 LED lamps
• Installation of a building automation system
• Introduction of an M-Bus meter concept for energy monitoring

Media: heating, cooling, electricity, light, steam

Contract term: 10 years

Customer benefit

• Reduction in total energy costs of EUR 1.1 million net per year
• Guaranteed savings over the term of the contract
• Assumption of maintenance costs
• Minimized risks, greater security of supply

Winner of the Contracting Award 2014

Benecke-Kaliko AG is part of the Continental AG group of companies. At the Eislingen plant, around 350 employees produce 133 km of film webs every day, primarily for the automotive and automotive supply industry. Customers mainly use the films for decorative surface coating. Benecke-Kaliko AG produces patented films under its own brand name.

SPIE Energy Solutions supplies the plant with media and ensures a significant reduction in operating and energy costs.

Requirements for

At its Eislingen site, the company, which is part of the ContiTech Group of Continental AG, produces high-quality technical and decorative surfaces for the automotive industry. The plant management was looking for a way to reduce the costs of energy-intensive production and increase capacities for core tasks. Energy management was therefore completely outsourced to a contractor.

SPIE Energy Solutions guaranteed cost reductions in the energy and media supply as well as greater security of supply and availability.

Results

The plant purchases process and heating energy, cooling water and compressed air from SPIE Energy Solutions and commissions them to clean solvent-containing exhaust air. The immediate optimization of the existing systems led to a five percent reduction in consumption after just a short time.

As a result, the engineers from SPIE Energy Solutions implemented a new energy supply concept. This included the construction of a new energy center. This houses both the new boiler house for steam generation and the new cooling center for the plant's cooling water supply.

In addition, the existing exhaust air purification system was replaced by a modern regenerative thermal oxidation system (RTO). This achieves significantly better emission values with considerably lower operating costs. Some of the pipelines for the plant supply were renewed. Benecke-Kaliko's investments amounted to over 5 million euros in total.

The eight Benecke-Kaliko employees who were previously responsible for energy technology are now employed by SPIE. The measures have resulted in a significant and sustainable reduction in operating and energy costs in the media supply; the contract term is ten years.

Services provided by SPIE Energy Solutions

• Plant refurbishment and new construction
• Plant operation, individual measures
• Construction of a new energy center for the supply of cooling water, steam and compressed air
• Replacement of the existing exhaust air purification system with a new RTO system for cleaning solvent-containing exhaust air from production
• Construction of a new water treatment plant to extract cooling water and boiler feed water from river water
• Installation of control technology for all technical supply systems
• Investment in plant refurbishment
• Implementation of various measures to reduce the customer's useful steam consumption

Media: heating, cooling, water, compressed air

Investments: 5.3 million euros,

Contract term: 10 years

Savings

• 24 percent savings in CO2 (equivalent to 3,796,200 kg CO2 /a)
• 48 percent savings in solvent emissions (equivalent to 4,045 kg C total/year)
• Significant and sustainable reduction in operating and energy costs in media supply

Customer benefits

• Lower energy costs
• Reduced emissions
• More security of supply
• Higher availability
• ISO 9001, 14001 and EMAS certifications lead to clearly structured processes and maximum safety

The German Villeroy & Boch Group is one of the world's leading ceramic manufacturers in the bathroom, wellness and tableware sectors - with 7,400 employees, 14 production sites and branches in 125 countries. Founded in 1748, the company today stands for excellent design, innovative technology and uncompromising sustainability.

The Group's headquarters is the Old Abbey in Mettlach, Saarland, which was purchased by the then owner Jean-Francoise Boch in 1809. The Mettlach sanitary ware factory was built in 1956 and modernized and expanded in 1967. Today, washbasins and toilets are mainly produced in this automated factory using a highly efficient die-casting process.

With its sanitary ware factory, Villeroy & Boch sets international standards in terms of environmental management: in 2009, the production facility qualified for the globally applicable ISO 14001 certification and was simultaneously validated in accordance with the EMAS regulation. this was followed in 2014 by ISO 50001 certification for the exemplary energy management system.

With the support of SPIE Energy Solutions GmbH, Villeroy & Boch was able to significantly reduce the sanitary ware factory's energy consumption in 2014 and make production much more sustainable.

Requirements

Large ceramic parts, such as a washbasin, have to undergo an energy-intensive process during production. In the past, the heat required for this was supplied by steam as an energy source. In the meantime, production technology has developed in such a way that the casting process has been converted from conventional plaster casting to the automated die casting process. Drying now only takes place in gas-heated dryers. This naturally has an impact on the energy infrastructure of production.

This is also the case at Villeroy & Boch. Following the modernization of the production process at the Mettlach sanitary ware factory, the steam supply was to be converted to more efficient energy generation.

Together with the energy experts from SPIE Energy Solutions, a concept was developed to supply the factory with heat and electricity in a particularly efficient way, both economically and ecologically.

Results

The measures developed by SPIE were installed in 2013 and 2014. The existing steam supply was replaced by a highly efficient energy center. This consists of a combined heat and power plant (CHP) with an output of two MWel and a boiler system with an output of two times 3.5 MW.

The CHP unit runs on natural gas and generates highly efficient heat and electricity. The electrical energy generated is used entirely in the sanitary ware factory.

SPIE Energy Solutions GmbH has installed a local heating network more than two kilometers long on the Villeroy & Boch site to distribute the hot water from the pumps. The result is impressive: The company's energy costs will be reduced by an amount in the high six-figure range in future. This corresponds to a saving of around 25 percent in relation to the original costs.

At the same time, the energy service provider SPIE Energy Solutions will reduce Villeroy & Boch's_{CO2 emissions} by more than 4,000 tons per year. An efficient step for environmental protection.

For a contract period of 10 years, SPIE will take over the operation of the systems, regular maintenance and repairs.

Services from SPIE Energy Solutions

• Plant optimization
• New plant construction
• Savings guarantee

Individual measures

• Construction of a new energy center
• Construction of a CHP unit with an output of 2 MWel
• Conversion from steam to pumped hot water
• Renewal of the boiler system to 2 x 3.5 MW
• Installation of a local heating network (2 km)
• Operation, maintenance, repair

Media: heat, domestic hot water, electricity

Contract term: 10 years

Customer benefit

• Greater process reliability thanks to the renewal of the heat supply
• Own power generation with the CHP unit
• Reduction in total energy costs of approx. 25%
• Reduction of environmentally harmful_{CO2 emissions} by approx. 4,000 t/a
• Guaranteed savings over the term of the contract