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Renewed refrigeration considerably energy-saving.

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Thanks to by Facta installed modern Grundfos pumps, energy costs are 64% lower.

Thanks to by Facta installed modern Grundfos pumps, energy costs are 64% lower. 

Efficient pumps quickly pay for themselves. That does Kivo Plastic Packaging prove, who  let Facta from Uitgeest renew the cooling system for extruders. Thanks to modern Grundfos pumps, energy costs are 64% lower. Kivo Plastic Packaging in Volendam, one of the largest producers of polyethylene packaging in Europe, makes films primarily for the packaging industry. The extruders are cooled with groundwater. The cooling system exists of two parts in which water circulates. There are two sources from which two pumps inflate groundwater. Throughout the year, this water has a temperature of about 12°C. The groundwater is led through plate heat exchangers in which cooling water is cooled and, with a temperature of 19°C, is re-injected into the ground. The second part of the system consists of pumps, valves and pipes that lead the cooling water along the extruders, gearboxes and printing presses. This part was due to replacement, says Erwin Posthumus, production manager technical service of Kivo. 

Weekly failure
‘We had two pumps, as well as two reserves of nineteen years old, to pump the cooling water to the extruders. In the end, we assisted every week to rectify a malfunction. Thus the system really needed to be replaced. Here Facta from Uitgeest, traditionally an overhaul and repair company for rotating machines such as electric motors and pumps, comes into the picture. Since 2010, the company is A-Partner of Grundfos. Accountmanager Eric Dijkhuizen was already familiar with the situation at Kivo, as his company provided maintenance there. I offered to, together with Grundfos, do an energy scan of the existing situation and to present an alternative pump system.’ This showed that a significant amount of energy could be saved by combining new Grundfos pumps with frequency inverters and by letting these increase and decrease speed based on the temperature of the water that returns from the machines. The cost saving was for Kivo one of the main reasons to replace the entire installation. Moreover, the maintenance costs are lower because the system has been completely revamped. 

Pump room
In the old system, the cooling water was pumped through the factory in two strands. These pumps were not regulated and therefore often provided more power than necessary. There was no separation between the cold and the warm cooling water. Moreover, the pump room was situated above the area where the low voltage equipment was mounted. Even though this in itself has never caused any problems, it naturally was not an ideal situation, according to Posthumus. The pump room was moved upon advice from Facta. The new cooling system includes significantly more components, says Vincent Groenendijk, accountmanager at Grundfos Netherlands. In total, now 14 pumps are installed. Seven of these are used, so that there is a spare pump for each pump that is used in the ordinary operation. The system also includes frequency inverters for each pump. Therefore, these do not need to rotate faster than necessary to pump sufficient cooling water around. A large part of the renovation of the cooling system consisted of the replacement of all pipes. The old pipes were of PVC and were subject to aging, says Dijkhuizen. We have replaced them with pipes of HDPE. Moreover, we have chosen a larger diameter. Should there ever be a need for more cooling water, then the system will already be suitable. 

Submersible pumps regulated
The two submersible pumps are not replaced, but they are equipped with frequency inverters. As a result, they use less energy. There is another advantage, as Posthumus states. By the adaption of the system, the submersible pumps now deliver cooling water where needed, thus less than before. The analysis of the pump system shows that the new system can save about 64% on energy. The payback period for the pumps amounts to two years. The system runs now almost half a year, thus this saving has not been fully verified by measurements, however Posthumus thinks that this will definitely be realized. We already see that there is a great saving. 

Total supplier
The operations at Kivo fit well within the development that Facta is experiencing, Dijkhuizen explains. We are becoming more and more a total supplier and installer instead of a company that supplies components and overhauls. With this order we show this, especially because we have realized the replacement of the pumps in three days between Christmas and New Year in 2013. Kivo has confidence in the company. This is, among other things, evident from the involvement of Facta in thie construction of a new factory for the printing of films in Kosovo. In the Netherlands, Facta will prefabricated perform the pump system for cooling this factory. Subsequently, complete units will go to Kosovo to be installed there. 

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