White PaperAutomotive
Discover How an Energy Check From Grundfos Helped a Global Automotive Leader Transform Their Cooling Systems for the Future
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When a global automotive leader with over 40 production facilities worldwide and over 100,000 employees focuses on improving energy performance and increasing efficiency throughout their operations, they turn to their energy managers.
Through a simple Energy Check with Grundfos for their cooling operations, they completely transformed their cooling system. Collaborating with Grundfos and EFS Haustechnik, they not only achieved unprecedented energy efficiency without disrupting operations, but also received several additional benefits beyond the initial expectations of energy savings, thanks to multiple technological upgrades and updates.
Download this case to read more about all the improvements and achievements in the automotive leader’s cooling system operations, thanks to a simple Energy Check, and imagine how your operations could be transformed!
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Overview
The white paper discusses the modernization of the cooling water management system at the Mercedes-Benz factory in Kassel, Germany, which serves as a global center for commercial vehicle axles and electric drive systems. The project aimed to enhance energy efficiency and reduce resource consumption in line with Daimler Truck's sustainability goals, including a commitment to CO2 neutrality by 2039.
Key improvements included the replacement of outdated pumps with more efficient end-suction pumps and the installation of speed-controlled pumps equipped with integrated frequency converters. This upgrade involved retrofitting two cooling tower pumps from 1996 and two system pumps from 2011, transitioning from four high-power 45 kW pumps to five lower-power 15 kW pumps, resulting in a total power reduction from 180 kW to 75 kW.
The new system features additional sensors for monitoring volume flow rate, pressure, and temperature, along with a Control MPC-E pump controller that optimizes pump operation based on real-time data. The piping system was also adapted to accommodate the reduced pump power and water volumes, minimizing pipeline sizes and capping unused sections. This optimization has led to significant energy savings and improved operational consistency.
The project was a collaborative effort between Daimler Truck’s energy managers, Grundfos, and EFS Haustechnik, and it has set a benchmark for future upgrades of aging cooling water systems within the factory. The enhanced system is so efficient that there are considerations to shut down another cooling water system during summer months, further consolidating resources.
Overall, the modernization of the cooling water system in Hall 55 exemplifies Daimler Truck's commitment to environmentally friendly production practices, showcasing how technological advancements can lead to substantial energy and cost savings while supporting sustainability objectives.