insights 1-2012

Insights Information for customers and employees of the Hoval Group 1/2012

Renewable Energy!Solution-oriented and sustainable Hoval systems

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Introduction

We take a solution-orientated approach to everything we do

Customer surveys show us time and again that we, at Hoval, approach work in a particularly solution-orientated manner. This is great news to us, because this is a very important issue.

Our company founder Gustav Ospelt was an innovator who was willing to blaze new trails in order to come up with clever solutions. As a result, he has remained a lasting influence on the Hoval culture. As early as the 1940s, he developed a solution that made it possible to cook food and provide heating simultaneously using a central heating stove. The first boiler with an integrated hot water tank, known as the Hovaltherm (nicknamed "the rocket"), followed in the 1950s. The Hovaltherm conquered the market in Europe in the 1960s, with over 350,000 units sold. This pursuit of intelligent solutions has influenced our development ever since and has resulted in countless sophisti-cated products that are often one step ahead of the current market needs.

However, our solution-oriented approach goes beyond the development phase and has become a natural part of how we operate. Hoval provides premium products, but Hoval's true strength lies in the intelligent coordination of the systems.

Just as when preparing a meal, you need both the finest ingredients and capable people who can create a mouth-watering dish. It is therefore logical that we would place a high value on skilled employees. Consulting services exper-tise is very important to us, as you will discover in the various articles provided in this issue of Insights. From unique data centre air-condition-ing systems to the most sophisticated district heating projects with their own Hoval instrumen-tation and control systems, to bivalent operated heating systems—primarily operated using an alternative energy source—our experts are capable of providing energy efficient, customer-specific solutions that conserve resources. We are not afraid to provide a performance guarantee for the solution, because we know what we're doing, and because we are solution-oriented.

Dear Reader

Peter Gerner, Hoval Group Management Board/CEO Heating Technology

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Contents

Insights 1 / 2012

In focus

04 Top marks for Hoval’s system solutions.

05 Solar power for the Zentralfriedhof cemetery in Vienna.

06 Listed landmark restoration project uses biomass.

07 Pellet boiler for British swimming centre.

08 Hoval 2012 trade fair report.

In operation

10 District heating project in Stansstad.

12 Ventilation, heating, solar collectors for heating water.

14 Efficient air-conditioning of data centres.

16 Turning a residential building into its own power plant.

17 Heating comfort in the design hotel.

18 City West in Chur uses a Hoval heating system.

In the market

19 Double jubilee at Hoval GB. New Hoval managing directors.

20 Winner of the trip to Egypt. Hoval online news.

21 A closer look at Hoval certification.Hoval Germany Heating Technology at new site.

22 Swiss planners visit the Hoval head office. "Make it in Great Britain" industry image campaign.

23 Hoval football: Euro 2012.

In detail

24 Robots on the night shift.

26 New BioLyt (8-36) has favourite technological features.

28 Heat recovery from exhaust air.

In retrospect

31 Solution-oriented since 1944.

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1 + 1 = 3

From a purely mathematical perspective, the sum above is clearly incorrect. However, from the viewpoint of a Hoval customer, 1+1 can indeed equal more than 2.

When Hoval products are added to Hoval expertise the end result is so much more than the sum of its parts.

Any solution can be considered as the sum of many components. It is how effectively these components are combined to create an efficient and effective system that makes all the difference.

The ideal starting point is to be able to choose from a diverse selection of solu-tions, such as a range of heating pro-ducts fuelled by different sources of energy – solar, wind, geothermal, wood, gas and oil. When combined intelli-gently, these elements can create a heating system that delivers distinct economic and environmental advantages to the customer. Not just now but throughout its life cycle.

Hoval climate technology solutions pull out all the stops when it comes to achieving the ideal interplay between heating, cooling and humidity.

The products are an essential ingredient, of course, but it is the expertise that goes with them that results in a precisely tailored system.

Knowledge from experience

For many years Hoval has continuously acquired knowledge and expanded its expertise, fine-tuning and re-evaluating in a constant quest for perfection. Since the mid-1900s the company has been known for its specialist expertise in oil and gas heating solutions. In the mid-1980s Hoval pioneered the use of biomass gasification technology, marking the transition from fossil fuels to wood fuels that we see today.

„Responsibility for energy and environment“

This principle is clearly evidenced by the shift in the proportion of sales from heat generators. Today, over 40% of Hoval sales are accounted for by heat generators that use renewable energy sources. These include solar thermal, heat pumps, wood pellet and wood chip fired boilers. Indeed, Hoval now offers over 600 standard systems, supported by a planning office for individualised plant systems at the head office in Vaduz.

Quality based on experience. Top marks for Hoval system solutions

One-stop expertise

There are some who say that it is impossible to do it all. However, it is possible to be a specialist in multiple fields – especially when every technology is thoroughly understood from first principles to its most advanced applications. In-house expertise can be supplemented with specialist input from other parties to continually build knowledge and understand how that knowledge can be applied to maximum effect.

These are the factors that drive a systems-thinking approach that adds value for the customer

And the best thing is that practically all of that knowledge is housed in a single entity (Hoval) and the customer can access it from a single source (Hoval).


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Insights

Austria

Solar power for the Zentralfriedhof cemetery in Vienna.Famous historical figures have found their final resting place in the Zentralfriedhof of Vienna. Three million people are buried in this world-renowned cemetery. Now it runs on solar power.

The Vienna Zentralfriedhof can be still and dark, but also melancholically mellow. If you pass by the grave of Johan Strauss in this cemetery (the second largest in Europe), for instance, you may hear one of his merry waltz melodies in your mind. Or at the grave of actor Hans Moser you might hear the constant, slight twang of his voice. But perhaps the grave of Falco is what you're after. His fans still lay fresh flowers next to his grave, even 14 years after his accidental death.

The Vienna Zentralfriedhof boasts 2.5 million square metres of Viennese history and folk lore. It immortalises artists and philosophers, scientists and athletes, and it brings together the memories of people of all religions.The extensive grounds with its alleys

and paths requires maintenance and care. The employees have their own kitchen, and after finishing their work they can shower and change their clothes on site.

80 m2 solar collectors

The energy required to prepare hot water for the kitchen and the washroom facilities has been supplied by the sun for a few months now. In accordance with the plans by project manager Anton Rapp from the engineering company Allplan GmbH, Hoval GFK ALGT, 10 solar modules were installed on the roof. The eight large-scale collectors cover a total of 80 m2 and are combined with the Solex HZL Max solar stratified charging module. The Hoval LSF 2000 charging tank is equipped

with the compact Legiostop WWK 200 hot water charging system. To cover peak loads and to heat the rooms, including workshops in the winter, a Hoval UltraGas® (400) condensing boiler is also at the ready. A Hoval EnerVal 4000L buffer storage tank serves as the "thermal battery" and intermediate storage tank until the heat is required.

When the sun shines on the Vienna Zentralfriedhof, it now takes away a bit of the drama from the sentimental stories and adds a bit of hope instead. It is the story of the present, covering state-of-the-art heating technology that helps conserve energy. No emotions are involved, but it is highly efficient.


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As a result of the strategy by the National Trust to reduce emissions at as many national estates as possible, two oil-fired boilers in Sudbury Hall were replaced with two Hoval pellet boilers. During operation, annual carbon emissions can be reduced from the previous amount of over 52 tonnes to the current amount of less than 12 tonnes.

Sudbury Hall is a former private estate from the 1600s listed as a historic land-mark and currently houses the Museum of Childhood, among other things. Some exhibits at this museum are sen-sitive to changes in temperature and humidity. A reliable and accurate oper-ating heating system was therefore crucial in guaranteeing the protection of these national treasures for the future. The trust decided that the Hoval STU biomass boiler would be the best replacement for the existing oil-fired boiler.

"The National Trust is com-mitted to installing renewa-ble-energy technologies in its properties wherever appropriate. The fact that we were able to source both the boilers and wood pellets locally also helped to reduce the building’s carbon footprint."

Charles Robinson, the National Trust’s senior building surveyor

Before the two Hoval pellet boilers and custom pellet storage room could be installed, the 12,000 litre oil tank for the old boiler had to be safely removed. Hoval diligently handled this task up to the point of commissioning the new Hoval boiler.

The listed status of Sudbury Halls also means that no external modifications may be made to the building's envelope or façade. In a bold step, a crane first had to lift the boilers above the building and into an inner courtyard. From there the boilers were transported through existing cellar corridors to the boiler room. This project was anything but child's play and yet it was accomplished in just six weeks. Solution-oriented thinking not only makes the impossible possible, but also saves time and money.

United Kingdom

Historic stately mansion benefits from heating with renewable energy.The British National Trust, dedicated to preserving monuments and protecting the environment, is increasingly choosing renewable energies for its restoration projects. Two Hoval 150 kW STU pellet boilers reduced carbon emissions substantially after the conversion from oil to wood at the listed landmark Sudbury Hall in Derbyshire.

Sudbury Hall, courtesy of National Trust Images, Andrew Butler, photographer.

A logistical master achievement: a crane lifts the pellet boiler into the inner courtyard of the listed building.


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In March 2009 the doors of the Notting-hamshire district pools were closed for a 5 million pound renovation. One of the main reasons for the renovation was the aim of creating an efficient, low-carbon emissions leisure centre. The centre chose biomass for the heating system, which should reduce carbon emissions at the facility by approximately 4000 tonnes in ten years. The 425 kW Hoval pellet boiler provides the entire heating and hot water supply for the leisure centre, including the main pool and training pool as well as showers. Thanks to the temperature control system, the water temperature remains a constant 29°C and the air temperature is a steady 30°C. Rebecca Adlington learned how to swim

at this facility when she attended Mans-field District Council swimming lessons at the age of four. She later joined the Sherwood Colliery Swim Club. Her talent was spotted at the age of nine and she was selected to join the Nova Mansfield Development Squad. She quickly qualified for the A squad before ultimately training with the Nova Squad in Nottingham at the age of 14. The pool where Rebecca took her first swim strokes is now gold medal worthy. It features an extra long training pool with a counter-current system, which helps top athletes in particular, improve their technique. In addition to a new, public changing area, the centre has changing rooms for schools, clubs and the disabled as well as a state-of-the-

art fitness studio with 44 workout stations. In addition, the architecture of the swimming centre roof dates back to 1934, when it was originally built.

United Kingdom

Hoval biomass boiler significantly reduces carbon emissions in new swimming centre. Two Hoval pellet boilers are heating the renovated swimming centre where Rebecca Adlington, the two-time Olympic gold medal winner and bearer of the Order of the British Empire (OBE), once learned how to swim.

Rebecca Adlington, image courtesy of Mansfield District Council.


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Swissbau Basel

In the key Swiss market for Hoval, a technological perfor-mance show took place in an approximately 270 square metre area and boasted a visual innovation: the new product design in Hoval red. The "Power in Red" was not overlooked and once again proved that an attractive design is almost as important as the high-tech features inside the equipment. Highlights included Hoval gas condensation technology as well as the Hoval heat pump and fuel cell research project. A total of 115,000 visitors, the majority from Switzerland, attended the five-day trade show to catch up on the latest in building technology.

Auquatherm Vienna / Energiesparmesse Wels

Completely in line with future trends, Hoval primarily focused on presenting its new combined heat and power plant and district heating business line with transfer stations as well as the new Hoval instrumentation and control system at the Vienna show. At a press conference, the exchange of data and data processing by Hoval TopTronic® com and TopTronic® supervisor were explained to trade journalists. The Hoval BioLyt (8-36) pellet boiler was presented as a new product at the Energiespar-messe in Wels, Austria. The boiler premiered successfully and is a genuine solution for energy-efficient heating with wood.

Further information on the new BioLyt (8-36) can be found on page 26.

Trade fair report

Hoval's trade fair focus: renewable energy and energy efficiencySpring is traditionally the trade fair season for the heating and climate technology industry. Hoval exhibited at the most important major international trade fairs in 2012. The focus was on Hoval system solutions and dealt with the issues of energy efficiency and renewable energy.

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The protagonists of the trade fair in red: the redesigned Hoval boiler.

Hoval district heating instrumentation and control systems and "girl power" are a perfect match.

Swissbau Basel Auquatherm Vienna / Energiesparmesse Wels


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Mostra Convegno Expocomfort in Milan

Hoval made its presentation, focusing on five market-related topics: HVAC system solutions in low-energy houses, the best renovation options, heating with biomass, solutions for community residential construction and for large facilities. Sustainability, energy efficiency and renewable energy are a key desire in Italy for counteracting the effects of global climate change. By contrast, in the Hoval Alps cinema, it was all about films, popcorn and conversation, encouraging both professional and social networking.

IFH intherm Nuremberg

Even in Germany the core message presented at the Hoval trade fair stand was energy-efficient system solutions. As a full-service provider, Hoval scored top marks with one-stop solutions for single family homes and residential buildings, new construction and renovation as well as systems for utilis-ing local heating. In addition to proven Hoval gas condensa-tion technology, heating with biomass and Hoval heat pumps were also topics of discussion. The new VarioVal buffer storage tank and the HomeVent comfort ventilation system as well as climate technology solutions complemented the Hoval product portfolio. Over 47,000 visitors from the industry attended the four-day trade fair to catch up on the innovations and trends in the HVAC and sanitation industry. Heike Mahler looks forward to greeting trade fair guests in Nuremberg.

The highly skilled Hoval Italy team arranged for informative trade fair days.

IFH intherm Nuremberg

Mostra Convegno Expocomfort in Milan


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Connecting to a multiple source district heat network means paving a path to a bright future: because it removes boilers and separate heat pumps from the picture, only a small amount of money is needed to cover hot water and space heating requirements. In fact, all that is needed aside from this is a single station for transferring the district heating from the network to the house. What is more, in some cases, contractors are even willing to cover the costs of these instal-lations themselves, so all the owner has to pay are the electricity and heating bills. And to top it all off, the environment generally benefits from systems of this type as well. All this makes district heat-ing a highly appealing choice. But while the goal might bring huge rewards, getting there is an arduous process for the contractor – that is, unless they choose the right solution oriented partner for planning and setting up the district heating network. For his part, Reto Nufer, Head of Sales and Service at Hoval's office in central Switzerland, often considers the process in terms of a Venn diagram, thinking about how the different circles within it engage, overlap, and merge to form one large circle.

Using heat gains from a sewage treatment system

Taking the example of the Stansstad pro-ject, Swiss company EBM occupies the first circle in the hypothetical Venn diagram. A cooperative with an interna-tional presence, the company focuses its efforts on renewable energies and supply security in equal measure. It was EBM who brought the idea of a multiple source district heat network to life at the

Rotzwinkel sewage treatment system in the Stansstad residential and commer-cial district. The second circle encom-passes a heat generation study carried out by engineering firm Karl Graf. A wood chip furnace represented one of the two types of heat generation it con-sidered as part of this study. The other, meanwhile, was based not only on heat pumps that could use the heat gains from the Rotzwinkel sewage treatment system, but also on an additional oil-fired furnace designed to cover peak loads.

The second option came out on top – and created the third circle in the process: for the heat transfer stations in the 30 buildings that were to be connected to the network, Hoval was able to provide everything from a single source without involving subcontractors.

Six weeks for each transfer station

Hoval's central Switzerland team set up a project group in order to coordinate its skills and areas of expertise more closely – and to allow quicker execution

of the project as a result. This is also where the second and third circles started to overlap. The team provided specifications for each of the 30 Hoval TransTherm transfer stations and defined the size of the plate exchangers, as well as other parameters, according to output levels. Prior to this, Karl Graf had already coordinated the specific heat demand of each individual building with the heat profile of the network, and then took on the task of releasing each of the custom-designed transfer stations for production.

"In terms of the time required to produce a Hoval transfer station in accordance with its individually specified dimensions, following the specification release stage, we only needed around six weeks".Reto Nufer, Head of Sales and Service - Hoval Switzerland

Switzerland

A multiple source heat network that offers more than just heat.Setting up a multiple source district heat network is a complex task. But clients and planners can speed up the work involved considerably by joining forces with the right technology partner. Thinking about the roles that people play in the process is just as important as creating the right custom technology for the job –during service and installation phases alike. Here we take a look at one example from Stansstad, in the heart of Switzerland.

People(Service)

EBM/private andcommercialcustomers Hoval AG

Organisation

People(Service)

Organisation

Technology

Win – win situation


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Heat generation:■ Heat gains from sewage treatment

system used as heat source for heat pumps. Rotzwinkel sewage treatment system in Stansstad, Switzerland

■ 2 heat pumps, each with 600 kW output

■ 2 oil-fired boilers, each with 1500 kW output

■ Subscribed heating capacity approx. 2500 kW

■ Goal: 85% coverage purely through heat pump energy

■ CO2 reduction of 1400 tons per year

Network:■ Closed network

■ Around 3 km

■ District heating flow/return temper-ature in winter 65°/45°

■ Maximum pressure 6 bar

Transfer stations:■ Hoval TransTherm CAD

■ Output 15-190 kW

■ Total of 30 systems

Technical data

Three more circles

The project has now turned to Reto Nufer's Venn diagram for a second time. As before, it contains three circles, but this time (as the figure below shows) they represent technology, people, and organisation. Although the technology component is obviously significant in size, the circle representing people is only marginally smaller: after all, it is the people who combine the technology to form a complete energy-efficient solu-tion, and who enable the project to come to fruition both efficiently and effectively. Not only that, but it is also the people who have the role of provid-ing any support necessary during oper-ation further down the line. And that means it's a win-win situation for every-one: the sewage treatment system operators in their role as the heat sup-pliers; EBM as the investor; the cus-tomer and contractor; Karl Graf as the planner; Hoval as the technology sup-plier; local heating system installers; and, of course, the end customers.

As Reto Nufer puts it, "This way, we're bringing everything full circle."

Hoval: A faithful partner

Hoval's work, however, doesn't stop with the scrupulous service it provides in commissioning the heat transfer stations: "We also offer reinspection and readjust-ment following the initial heating period, plus a whole range of service and main-tenance activities", explains Reto Nufer.To cover the period after the system warranty has expired, he recommends Hoval Switzerland's TopSafe® mainte-nance concept: "This provides one maintenance session per year and there are no hidden charges to cover the service technician's travel costs or time on the job." But the best part of this maintenance contact is Hoval Switzer-land's on-call service. Thanks to this, there is always someone available to help customers around the clock, 365 days a year. So it is not just Hoval's cut-ting-edge technology that makes a real difference.

Hoval AG


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A complete Hoval solution – with end-to-end efficiency.It's a simple formula: solution-oriented customers need solution-oriented suppliers. At its site in the Hungarian city of Kecskemét, the Hilti company produces chisels, drills and diamond drilling core bits. When it decided to extend its production facilities, it turned to Hoval to provide everything from a single source: this included ventilation and heating systems as well as solar collectors for water heating. Now, the complete system that Hoval has created saves energy, time and money.

Just like Hoval, Hilti has its roots in Liechtenstein – but this isn't the only thing the two companies have in common. They also share a similar corporate philosophy which believes that employees who are enthusiastic about the technology they are working with, and who focus on the needs of the customer, are the key to creating products and systems that fre-quently surpass customers' expectations.

And the Kecskemét site lives by this principle too. When it took the decision to extend its production facilities, estab-lished in 1989, its intention from the very start was to recover heat gains from the production plants and use these for heat-ing purposes. This meant that it would only be necessary to use a heating boiler for covering peak loads. As well as this, the company set out a plan to heat water using solar energy, something that would reduce the amount of required heat out-put even further. For the planner responsi-

ble for the project, working in conjunction with Thermotrade (Hoval's long-standing sales partner in Hungary), opened up the possibility of lowering the original output from 1700 kW to 900 kW –more than enough, according to the thorough calculations that were made, to cover the facilities, even once they had been extended from 2500 to 5200 m2. The result is that the site now boasts a Hoval UltraGas® (900D) condensing boiler – the D stands for "double" to indicate its double-boiler design.

A boiler that does more than just heating

On average, the standard utilisation ratio of the Hoval UltraGas® condensing boiler reaches an impressive 110% (rel-ative to CV). The appliance also fea-tures a built-in Hoval aluFer® heat exchanger, which not only has a finned structure that increases the heat

exchanger area five times over, but also efficiently cools the exhaust gases flowing through it until they reach conden-sation point. In turn, the energy that is released as a result can be supplied to the heating process. For large installa-tions like this one, an UltraGas with dual cascade arrangement is the perfect

Hoval water heating system using solar energy.

Hoval RoofVent® LKW. Supply and extract air handling unit with energy recovery.


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30 collectors on the roof

The roof of Hilti's Kecskemét plant now also features 30 solar collectors com-prising a total area of 75 m2. Water is heated using the energy that these supply. The solar energy itself is stored in buffer tanks, which cover hot water demand.

Making savings through ventilation

The Kecskemét plant extension was carried out in two stages, one involving a 600 m2 building for product tests and the other a 3000 m2 production hall. The facilities also offer 1600 m2 of

space for logistics and administration.Seven Hoval RoofVent® LKW-9 roof ventilation units have been installed for the purpose of ventilating, heating and cooling the new halls. In the case of one hall, erected in the 1990s, the four RoofVent® units it features have been upgraded to LKW types and fitted with state-of-the-art controllers, thus enabling them to remain in use. The ventilation units reduce the temperature stratification in the room, which minimises heat losses via the roof. What is more, they can each be controlled individually, further reducing energy consumption. As a result, this decentralised Hoval RoofVent® roof ventilation system, which does not include any unwieldy air ducts at all, can boast energy-saving credentials that are far superior to its bulky, centralised counterparts. And to top it all off, maintenance can be per-formed on the units during production.

Since Hoval's complete solution was identified as the right choice for the job, the system has now been installed. Not only does it surpass standard levels of energy efficiency, but the word from employees at Hilti's Kecskemét site is

that they are thrilled with the new installation. "We're working in a healthy environment," they state –and no doubt mean this in more ways than one.

Nestlé is one of the biggest household names out there. A company with Swiss roots, it has 328,000 employees across the globe and covers every market – offering foodstuffs from baby food to coffee and juices, right through to soup and pasta.

Nestlé established its presence in Hungary in the early 20th century and now manufactures cocoa and coffee products in Szerencs, bottles mineral water in Kékkút, and produces chocolate in Diósgyőr. Finally, the town of Bük is home to a 50,000 m2 Nestlé factory site – the largest animal food factory in Europe. These premises also serve as

Nestlé's headquarters for central and eastern Europe.

The newest of Bük's production halls covers an area of 10,000 m2. Here, six Hoval RoofVent® LW 10 roof ventilation units are used to supply fresh air to re-creation areas. Each of the units can be controlled individually and feed in 8000 m3 of supply air per hour – and thanks to the Hoval Air-Injector, the supply air that the recreation areas receive is draught-free.

The special design of the units is able to cope with the higher-than-average level of humidity in the extract air, as it features coating on both the inside and

out and therefore offers corrosion pro-tection. In addition to their supply and extract air handling tasks, the units also carry out climate control within the area by heating and cooling the supply air. This decentralised system does away with the need for ventilation ducts, and its integrated heat recovery function brings energy savings too.

At the hall's opening ceremony, the healthy climate that Hoval's roof units are now producing made a real impres-sion on the VIPs in attendance – and it's something for which the employees who work in the hall every day are even more grateful.

A breath of fresh air for the industry's biggest player.Nestlé is both the world's largest food processing company and Hungary's biggest player in the industry. Approximately 1600 employees work at the four Nestlé Hungária Kft. production sites, with the facility in the town of Bük specialising in animal food. Here, Hoval has introduced a breath of fresh air into a new production hall.

Long-term benefits

"Our integral solutions make us stand out from the rest and have an impact on price: our customers benefit from not only lower procurement costs, but also lower operating costs.

What is more, the fact that they have just one contact for the entire project makes their lives much easier. With us, scheduling doesn't have to be a headache either – and nor does maintenance work further down the line. Our service technicians are extremely well versed in every area of their work. This keeps the amount of time and effort the customer has to spend to a minimum."

Remo Bettinaglio, Area Manager for Hoval sales partners in eastern and northern Europe


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Climate really matters in today's world – and that doesn't just mean the natural variety. If data centres did not have air conditioning facilities, the operating abilities of the servers they house would be thrown into jeopardy. And nowadays, it is data that keeps the world going round. Christian Richter, Hoval segment manager for data centres, gives one example of the consequences of server failure: "For a major bank, just half an

hour without data could result in losses amounting to several million euros".

Reducing high levels of energy consumption

A large number of companies and organisations make use of external data centres with the aim of maintaining security and availability in any circum-stance. International company e-shelter is one of the world's biggest providers of these centres: it designs, develops and operates them at a number of dif-ferent sites within Europe.According to Christian Richter, air con-ditioning accounts for up to half of the energy required by a data centre. "It's precisely in this area that

we can apply our expertise and provide a helping hand in the form of Hoval technology."

The name of the game: Energy efficiency

e-shelter currently operates a 1600 m2 data centre in the German town of Rüsselsheim. Here, it has brought Hoval's expertise on board in the key area of air conditioning: working together with specialists from e-shelter, a team from Hoval has developed a new, energy-efficient solution. Stephan Eder, Director Business Unit Climate Technology, and project manager Rolf Außerer, have devoted two years to the development project and the resulting system, named

Germany

Large-scale data centres gather, process and store countless quantities of data. And they have an appetite for energy to match. What is more, regulating their climate is a security issue too. In a bid to tackle this challenge, Hoval has joined forces with e-shelter – one of the world's leading data centre operators –to develop an energy-efficient solution. Featuring a modular structure, the new system can be tailored to meet the precise dimensions and requirements of data centres. Hoval's experience is helping to ensure this is a cutting-edge solution.

Helping data centres keep their cool.


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"Demand for air conditioning systems in data centres is set to grow even further. So the modularity that the ServeCool offers is a real asset."

Christian Richter, Hoval segment manager for data centres

Installing the units using a 70-ton crane. Nine ADK-30 units are used to cool one e-suite.

Hoval ServeCool, is now set for its large task that lies ahead of it. All 36 air con-ditioning units were delivered to Rüssels-heim in June of this year.

Innovation from experience

The new system incorporates two of Hoval's core areas of expertise: plate heat exchangers and adiabatic technol-ogy, which uses moisture to draw heat out of the air and cools the air in the process. The company's specialists are equally at home with both. Adiabatic technology is already used in the Hoval AdiaVent® recirculation unit, which has proven its worth in hall cooling pro-cesses. With the focus on the kinds of conditions that prevail in data centres, the combination of these two areas has resulted in the Hoval ServeCool air con-ditioning unit, supplied as the OEM product ADK-30 for e-shelter. The number 30 indicates the unit's ability to offer cooling performance at up to 30,000 m3 of air per hour. Throughout the year, the recirculation unit rarely has to turn to compressors for cooling pur-poses: "Additional mechanical cooling is only required if the fresh air itself is already very hot and also very humid – the kinds of conditions you'd see before a thunderstorm, for example", explains Christian Richter.

A unique combination

Christian Richter asserts that a combi-nation of fresh air-based free cooling and mechanical cooling like this, offer-ing the kind of efficiency that it does, is an unprecedented step. A good mechanical cooling system is able to achieve an Energy Efficiency Ratio (EER) of 4 to 5. "But this combination's energy efficiency value far surpasses that level, reaching more than 18", states the Hoval specialist.

Giant plate heat exchangers

The energy efficiency that the Serve-Cool is able to achieve is down to the plates used in the Hoval cross-flow plate heat exchangers. Featuring a lateral length of 1.20 m, they are the largest individual plates that Hoval, headquartered in Liechtenstein's capital Vaduz, produces in its "S" design. Accordingly, this dimension allows for higher-than-average temperature effi-ciency. In total, the nine air conditioning units installed over each 400 m2 area at the Rüsselsheim site will remove a heat output of 1 MW.

Sophisticated control technology

Expertise and experience are also at the heart of the new control system that has been developed for the Hoval ServeCool units. Specifically, the high security standards associated with the application demand a high-quality, reli-able system for measurement and control. This is what makes the solution such an amazing innovation.

Modularity provides a leading edge

"Demand for air conditioning systems in data centres is set to grow even further", says Christian Richter. "So the modularity that the ServeCool offers is a real asset. For example, if you're adding another e-suite for addi-tional servers to an existing data centre that features a ServeCool system, then the modular structure means it is really easy to install additional air conditioning units too." In fact, the Rüsselsheim data centre is proof of this: the nine Hoval air conditioning units are being incorporated as soon as a 400 m2 e-suite reaches its completion.


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The structural concept for a house that produces more energy than it consumes was developed by Wolf Haus.

A Hoval air conditioning system in an EnergyPlusHaus (CasaEnergyPiù in Italian).

Italy

Turning the residential building into its own power plant.They had a dream – and dared to dream it: in the South Tyrol municipality of Auer, prefabri-cated house specialist Wolf Haus, together with Hoval and other specialists, have managed to create a house that produces more energy than it consumes. In fact, its use of renewable energy is so efficient that it actually produces more than both it and its inhabitants need. That is why Kurt Schöpfer and his team have called it the EnergyPlusHaus.

"2012 is definitely going to be a signifi-cant chapter in the Wolf Haus company history", believes Kurt Schöpfer, who heads up Wolf Haus in Italy. Together with his team of architects and engi-neers, he made a dream that once seemed impossible come true:

A single family home that does not require any fossil fuel energy at all.

Its use of renewable energy is so efficient that it actually produces more than it needs, and as a result Kurt Schöpfer and his team have called it the EnergyPlusHaus.

"We managed to reach our goal after a year of intensive design work", states Kurt Schöpfer with more than a hint of pride. This was followed by another

successful step – a practical test phase during which a family actually lived in the EnergyPlusHaus. As a result, after two years the new concept is now ready for the market. And according to Kurt Schöpfer, it surpasses "every low-energy standard to date".

With its sights firmly set on energy effi-ciency, the team from Hoval Italy made a significant contribution to the new Wolf Haus building concept by providing the Hoval Thermalia®H (17) brine/water heat pump, which retrieves energy from the ground and uses this to heat the entire house. The power it requires comes from a photovoltaic system. Dehumidifiers regulate humidity levels while cooling is being carried out in the summer months. A Hoval EnerVal (800) storage vessel with fresh water module, combined with a solar installation, pro-vides the supply of hot water. Mean-while, the Hoval TopTronic®T feature is

responsible for all control tasks.The Hoval HomeVent® RS-250 comfort ventilation system, which is specifically designed for single family homes, plus two Hoval HomeVent® RS-180 systems, conserve energy resources by recover-ing heat, cold and in winter, moisture, saving considerably more energy than is required for running the house . Natu-rally, a solar installation also supplies power from the roof area.

Others said that creating a house like this was an impossible task. But Kurt Schöpfer and his team knew differently – and it was Hoval who supplied them with a key part of the system solution. With its high standard of living comfort on top of its matchless environmental credentials, this single family home concept has set a precedent for other countries. And feeding excess energy into the local grid can make it an even more profitable investment.


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As its tower looms prominently out of the ground, guests looking out of the gener-ous windows in this hotel's 118 rooms are rewarded with views directly over the Lake Neusiedl and Seewinkel national park, as well as the Parndorf Plain.

It is no surprise that ecological aware-ness really matters at this boutique hotel, which opened its doors in 2009. As part of its commitment, it obtains exclusively green electricity from Austria, has converted its entire lighting system to LED technology, and, when it comes to heating, places its trust

entirely in Hoval. This has included installing a condensing boiler in the form of a Hoval UltraGas® (600D) cascade in its boiler room. The double boiler has just one flue gas conduit, which makes installation a breeze and keeps investment costs low, and the dual cascade arrangement safeguards the supply to the hotel. The system achieves maximum efficiency and clean combustion thanks to aluFer® technol-ogy and the Ultraclean® combustion system. Meanwhile, the high and low temperature returns are ideally suited to underfloor heating and the hot water

supply. It's a system that is kind to both the environment and the balance sheet – giving the Pannonia Tower Hotel's owners two causes for celebration.

The result is that the Pannonia Tower Hotel can boast a complete system that is a true winner. What is more, the hotel's head technician, Engineer Markus Dikovits, is delighted with Hoval's customer service – quite simply, he knows that it can always be relied on. So the Pannonia Tower Hotel can give its guests a feeling of comfort and ease day in, day out.

Austria

A design hotel with a visionary thermal comfort conceptThe Pannonia Tower Hotel in Parndorf, located in the Austrian state of Burgenland, practises an environmentally friendly philosophy wherever it can. And Christian Kühnelt, who manages the four-star property, is awarding Hoval top marks thanks to its help in providing his guests with a comfortably warm climate.


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Switzerland

Something literally outstanding is happening in Chur.Chur is getting a new skyline and an impressive city-within-a-city, with two 79-metre office and residential towers being erected in its south-western district. The shopping centre in the enormous City West lower-level building is already open and, with the help of Hoval heating technology, has its first winter behind it.Exit the motorway to the south of Chur, in the direction of Lenzerheide or St. Moritz, and you'll encounter a picture showing a rather different city to the one that was there a year earlier. To borrow from architect Thomas Domenig, Senior in a recent interview, the scene has been transformed into something quite glamorous. His architectural firm, which he initially took over from his father and now runs together with his sons Jon and Thomas Junior, is respon-sible for the City West project and also represents its main investor.

In fact, even the bold dimensions of the new pair of towers are impressive. Each has 24 floors encased in a metal, glass and concrete facade, and from autumn 2012 onwards these will become home to upscale apartments, medical practices, offices and a hotel with around one hundred bedrooms.

The shopping centre at the lower level of the building complex comprises a total retail area of approximately 18,000 m2. It opened its doors back in November 2011 – with facilities includ-ing an underground car park and more than one hundred parking spaces. City West has also been integrated into the public transport network.

For the Domenig architectural firm, the use of energy is a key priority. The shopping centre uses three Hoval Ultra-Gas® (1000) condensing boilers, each boasting an output of 1000 kW. The triple cascade arrangement and the heating system are also controlled by Hoval's TopTronic feature. A modulation range of 199-3000 kW provides full coverage for the building's heat demand.


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France Spain Switzerland

United Kingdom. 50 years of Hoval UK – as if that's not reason enough to celebrate.

From 1961 to 2011: a respectable 50 years of Hoval's presence in the UK market. This called for a celebration for the staff at the Newark head office and the second production facility in nearby Lincoln. Today, Hoval is considered a specialist, particularly in the area of heating technology for large power ranges and most notably operates all facilities for the Royal Houses of Britain, in addition to operating industrial and government facilities. The Royal Warrant to Her Majesty the Queen is the highest distinction for quality and outstanding achievement in the United Kingdom.

Francis Brunn is the new manager of the Hoval France team as of February 1, 2012. The still quite new sales subsidiary, (established in

2008) with headquarters in Strasbourg, has redistributed its responsibilities in order to manage the expanded market strategic objectives successfully. Thus the former managing director Jean-Frederic Veith will use his solid product expertise to take the technical department under his wing and strengthen the technical sales side as head of Engineering and Projects.

After the suc-cessful consoli-dation of Hoval in Spain, Claudio Zion, a man with many years of professional business experi-ence, took over

management of and responsibility for the further development of the brand in the Spanish market on 1 April 2012. During the reorganisation, Inigo Rodriguez, who previously held the dual role as managing director and sales manager, is focusing on sales in the northern region of Spain.

The Hoval Group Swiss sales sub-sidiary will have a new Sales and Services manager as of 1 September 2012. Marco Letta will assume the position from long-

term managing director Jürg Nufer, who is retiring in 2013. Jürg Nufer has been extremely successful in managing the Hoval's destiny in Switzerland for dec-ades, and now he can look back at a significant career based on building up and expanding the company. He will continue to impart his valuable knowl-edge about Hoval to the Hoval Group even after he officially hands over the managing director position to Mr Letta on 1 September 2012.

The plant in Newark was the location of Farrar Boilers (founded in 1887) long before Hoval took over the boiler manu-facturing plant. The site has remained part of Hoval to this day, and over the past 125 years has become known for its expertise in boiler manufacturing.

The 50th anniversary celebrations attracted 250 invitees, including Group management from Vaduz and special guests from the political realm, such as the Councillor of the Nottinghamshire County Council, Keith Walker, who worked in production for Hoval for 18 years. Retired employees who have

experienced Hoval through different decades also attended and enjoyed the evening together.

Honouring various employees and their personal community achievements in 2011 was a highlight of the evening. The following people were honoured in these categories: Sales - Sion Pearce, Services - Ali Percival, Engineering - John Judson, Heart & Soul - Carol Bryan, Perseverance - Geoff Courtney, Metalworking - Tony Roche.

Congratulations on the double anniversary celebration: 50 years of Hoval Brand presence in the UK and 125 years of "British built boilers" in Newark!

Welcome to the Hoval Family. We wish all of our colleagues the best of success in their new positions!

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In recent years the Internet has become the primary medium for communication. Years ago it had already become the obli-gation of every company to own and maintain a professional website. Now this is no longer enough. At a time when a single online platform – Facebook – is used by more than 900 million people and the Internet penetration in our markets in particular is over 70%, having an online presence is becom-ing even more important.And Hoval is in the midst of it all. Viral marketing activities have increased in the Hoval markets: for instance, an iPhone app has been developed for the Swiss market which quickly and easily calculates the possible returns and costs for gen-erating hot water or electricity using solar power. A QR (quick response) code has been developed for Austria for the "Envi-ronmental Support 2012" campaign.

Similar to a barcode, a QR code is recognised by a smart-phone and forwards users to a website where additional infor-mation can be accessed. It is fast and paperless. Registering for the Hoval Heat Recovery Symposium this Sep-tember can also be done easily online using state-of-the-art technology by filling out an Internet form or by linking a QR code to a mobile page. A partner portal was launched for installers in Austria in May of 2012 where customers can exchange points for products and advertising. And the Hom-eVent business line is running a Google AdWords campaign to expand advertising even further in this area.

A lot is happening in the digital world of Hoval.

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Liechtenstein. An online presence is more than just a website.

The contest from the last issue of the Hoval Insights magazine inspired over 2500 participants to tackle the question in detail. Observant readers could find the answer in the article on Hoval reference systems in Egypt, and a one-week trip for two at the Hotel Maritim Jolie Ville Kings Island Luxor, the particular holiday site that was equipped with a Hoval system, was promised to the winner. A winner has been chosen from among the correct entries: Andreas Widl, Managing Director of the Harrer GmbH&CoKG installation company in Pfarrkirchen, Germany.

Congratulations and enjoy your holiday!

Germany. Seven days of pure relaxation – Hoval makes it possible.

Winner Andreas Widl accepts the prize from Hagen Jakubek, Regional Manager of Hoval for south-east Germany.

inspired over 2500 participants to tackle the question in detail. Observant readers could find the answer in the article on Hoval reference systems in Egypt, and a one-week trip for two at the Hotel Maritim Jolie Ville Kings Island Luxor, the particular holiday site that was equipped with a Hoval system, was promised to the winner. A winner has been chosen from among the correct entries: Andreas Widl, Managing Director of the Harrer GmbH&CoKG installation company in Pfarrkirchen, Germany.

Winner Andreas Widl accepts the prize from Hagen Jakubek, Regional Manager

Photography contest on Facebook

We are looking for the best 12 photos covering "unusual mountain regions and weather conditions" for the Hoval 2013 calendar. After all, Hoval has its roots where weather was "invented", in the Alps.We are there-fore the most familiar with climate – inside and outside. Enter the contest and send us your most unusual mountain theme, including weather, and be one of the top 12 to win a cool Hoval hiking rucksack, and of course the calendar with your photo in! All of the contest details and conditions ofparticipation are available atwww.facebook.com/HovalGroup

To Egypt with Hoval


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Liechtenstein. Hoval's responsibility for energy and environment can be measured and certified.

After almost two decades at Karl-Ham-merschmidt-Strasse 45, the Hoval Aschheim office has moved. Geographi-cally speaking, the change is minor – barely 500 metres away - yet the move has had a noticeable and drastic impact: a sign of "decampment". The next step is to create a new, modern central heating system for the entire building: an Ultra-Gas® (250) and a BioLyt (160) unit will supply heat starting in October. The comfort ventilation system Home-Vent RS-250 and RS-500 will supplyfresh air to the Hoval conference rooms.

The Hoval Germany team welcomes you to Humboldtstrasse 30 in Asch-heim.

Germany. New premises.

Responsibility also means defining, implementing, verifying and continually optimising business processes. At Hoval, we take this responsibility seriously and maintain a quality and environmental management system certified in accord-ance with ISO 9001 and ISO 14001.

What does this mean in practice?

First there is the standard. This defines the requirements for a valid management system. The standards include, for instance, ISO 9001:2008, which defines the requirements for a company’s quality management system, and ISO 14001:2004, which defines the requirements for a company’s environmental management system. Independent, external, accredited specialists check annually to determine if the company is fulfilling all of the standard’s requirements. What is impor-tant to understand in this case, is that the two management systems are not independent systems, but rather an integrated system with the aim of con-tinually improving all areas within the business. The position of quality manager within the company is important in order maintain proper quality control. Martin Corradini holds this position, working with his team at Hoval in Vaduz. The team also issues the management system manual, which describes the company and its processes and serves to help employees complete

their daily tasks successfully and in accordance with the standards.

What makes these two processes so important to Hoval that they have to be certified?

Quality management system comprises the terms “quality” and “management system”. A management system is generally the interaction of all manage-ment activities related to diagnostics, design and verification. The term “quality” describes the results of controlled processes (not only product-related), or quality is also when the requirements and cus-tomer expectations are fulfilled. In an environmental management system, the aim is to comply with applicable legal and environmentally-related obligations in order to avoid impacting on the environment and to improve all relevant requirements on a continual basis. These are noble objectives which Hoval consistently takes into account and continually optimises for all of its processes.

In addition to these ISO certificates, the Hoval plant in Vaduz and various other sales subsidiaries can show proof of additional certificates in

a wide variety of areas. Sounds demanding, but that is also a core value of the Hoval brand!

The most recent certifi cation for Hoval, which does credit to the company’s claim of “Responsibility for energy and environment”.


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United Kingdom. Make it in Great Britain 30 Under 30.

Switzerland. Planner's Conference.

Great Britain has launched a campaign called "Make it in Great Britain 30 Under 30" which aims to showcase 30 young engineers and demonstrate the different aspects of manufacturing along with what it can offer in terms of careers from various branches of the industry. Young engineers across the country entered, describing their job, branch of industry and emphasis on what responsibilities they have despite of their young age. The campaign tackles two fronts: it makes a career path in industry appealing to young people by providing

On the occasion of the 2012 Hoval HLK Planner's Conference, Hoval granted 150 Swiss planning engineers a behind-the-scenes look at the head office in Vaduz over two days. In addition to sharing technical expertise on daily work, insight into the near future was the focus of the conference. System technology emerged as one of the key topics. Without the ideal interaction between all components, it is not possi-ble to develop an operationally safe and energy efficient system. One highlight

firsthand experience and it encourages industry to commit to offering young people a foot in the door to a professional career.

It goes without saying that Hoval UK participated in this competition in which a total of 30 young people were nominated after being selected by a jury of experts. Rebecca Chapman is one of the selected "30 under 30" who is now a PR spokesperson for Hoval in a current media campaign in the UK in which she talks about her tasks at Hoval. In her position as Marketing Projects Engineer at Hoval, Rebecca was responsible for managing the project of introducing the air/air plate heat exchanger production line to the Hoval plant in Newark.

was the presentation by the energy and peace researcher Dr. Daniele Ganser. The four key topics - Hoval system tech-nology, district heating, indoor climate systems and heat pumps - were each covered by specialists who explained the added value of Hoval technology by working hands-on with the product. Of particular interest were innovations such as Hoval's TopTronic® supervisor instrumentation and control system in the still quite new district heating network business line. This is an intel-ligent communications centre that guar-antees the secure and comprehensive exchange of data between the district heating transfer station and the district heating instrumentation and control system. Planners could also analyse Hoval's PowerBloc combined heat and power plant up close for the first time.Heat pump technology has been a key topic at Hoval since the early 70s. The new, ultramodern test bench in Vaduz uses a climate chamber to simulate various outside temperatures which Hoval heat pumps must withstand during operation. Continual improve-

The entire Hoval Group heartily con-gratulates Rebecca on her achievement and sees her nomination as a testament to the fact that jobs in the industry and particularly at Hoval are so multifaceted and appealing that they can inspire people beyond the boundaries of the company.

ment of energy efficiency is the primary focus when developing each unit.The second key business unit of the Hoval Group is Climate Technology, which impressed the specialists with new systems such as Hoval's EcoLine for sophisticated air conditioning requirements or Hoval's ServerLine for cooling data centres. These special solutions are designed for security, safety, hygiene and energy efficiency. Hoval has been successful for years in the field of large space climate control thanks to its decentralised systems which optimise the entire HVAC process. Comfort ventilation supplies constant fresh air at ideal humidity levels to living and work spaces. This controlled living area ventilation system is an attractive technology to modern planners and can be ideally integrated into the overall climate control design of the building--particularly in the case of new construction.

Rebecca Chapman is one of the top 30 employees in industry under the age of 30 in the UK. Congratulations!

Jürg Nufer, Managing Director of Hoval Switzerland, welcomes conference guests


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The ultimate competition

23 June 2012, Triesen, Principality of Liechtenstein: The stars were aligned for the event. The sun shone brightly from morning till evening. Eight teams and 15 countries met at the football pitch. Some of the teams had travelled great dis-tances to attend. It was the ultimate small pitch competition. In the face of the UEFA Euro 2012 in the Ukraine and Poland, the Hoval teams have developed a great ambition to "bring the cup home". Suspenseful duels, a lot of goal kicks and spectacular solo attempts were the order of the day. It was player against player, ending with the playoffs and an exciting final match. The defending champion Liechtenstein was

clearly able to deter-mine the outcome with a final score of 4:0 against Slovakia in the final match. The winner at heart was the Inte-grated New Market (INM) team, with members from eight countries who could not train together prior to the event. But the important thing is that they participated. The players with the fewest penalties were also rewarded. The Swiss team was able to capture this prize with only four fouls in nine games.

They celebrated after the game...

...with plenty of food and drink for everyone. Around 300 guests indulged in their choice of drinks and BBQ food. They celebrated until the early morning hours. Then at 2:00 in the morning all lights were put out and the last guests and helpers said good-bye.

The teams, including the defending champion Liechtenstein, are already looking forward to the Hoval World Cup Soccer Championship in 2014.

Liechtenstein. Kick it like Hoval.

RANKINGS:RANKINGS:

1. Liechtenstein

2. Slovakia

3. Austria

4. Italy

5. Switzerland

6. Germany

7. UK

8. Integrated New Markets


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It was one of the robots' shape and function that gave it the name "L-Wender": (or in German, “wendet”) taking the form of an "L", it turns boiler bodies into the correct position. In doing this, it sets the stage for the top gantry boiler welding system, which has the job of welding together the individual components that have been pre-tacked. These two massive robots work in perfect harmony with one another – and have done for years.

What they are assembling is something unique to Hoval: the aluFer® heat exchanger draws maximum heat out of every single drop of oil and every last hint of gas. This is what gives Hoval's highly popular, proven-in-practice UltraOil® and Ultra-Gas® condensing boilers their exceptional levels of energy efficiency. The sophisticated technology in Hoval aluFer® heat exchangers achieves unrivalled peak efficiency values. The aluFer® pipe boasts a long life-cycle that is down to the stain-less steel used on the water side, and thanks to its self-clean-ing function, it hardly requires any servicing work. What is more, the large surface area for partial load condensation enables peak values to be reached – with efficiency remain-ing at the same high levels.

The L-Wender and top gantry system have been specially designed to work with heat exchangers for boilers with outputs of between 125 and 1000 kW, although they can also handle equipment with outputs of 15 to 1000 kW.

The new additions – doing it for themselves

Not too far away, on the other side of the production hall, are two state-of-the-art robots which are comparatively delicate in size – one for handling and one for welding processes. These have been in place for a few months and operate without fixing devices – or are "jigless", to use Head of Pro-duction Hans Beck's words.

Liechtenstein

Robots on the night shift.The production site at Hoval's headquarters in Vaduz sees welding activities continuing day and night – and even at the weekend. Recently, however, it drafted in some extra help in the form of four robots. The two newest members of this team might be small by comparison – but they still have a significant role to play.

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"The heat exchangers that require welding no longer need to be fixed in place manually. The handling robot itself takes them from the conveying system – which is also new – and this system brings the finished units to the other side of the hall."

Hans Beck, Head of Production at Hoval

The automatic supply feature also means it is possible to prepare eleven units on the conveying system in the evening, before close of business. When the doors reopen the next morning, the fully welded units are then ready and waiting.

The new robot system is designed to handle 18 aluFer® types of different sizes, covering a heat output spectrum of 15 to 300 kW. To process one of the smaller types, the robots need around

three-quarters of an hour. Conse-quently, eleven jobs for smaller boilers make up an eight-hour night shift. The larger types require up to three hours – so the robots work over the weekend in these cases. Finally, the very largest are left to the L-Wender and top gantry system: once the necessary manual preparation work has been carried out, this equipment requires a full seven hours of work on a unit – or one night shift.

Better agility, higher intelligence

The new handling robot is more agile than the L-Wender and can turn a heat exchanger about multiple axes. Mean-while, the new welding robot is more intelligent than the top gantry system. The three welding torches calibrate themselves, for example, which ensures that pressure vessels, heat exchangers, boiler shells, bases and covers are always welded with accuracy at exactly the same points. Therefore, as well as enabling unmanned shifts and creating time savings as a result, this technology brings yet another advantage – even more consistent quality.

Human interaction

The levels of reliability that Hoval technology offers are created right at the production stage. Production needs to be economical and afford-able, so quality and throughput have to remain constant. The production team have developed their methods based on these two key considera-tions. The degree to which automa-tion is incorporated is an equally important factor.

When two robots have to work in syn-chronism, the system becomes more complex and more sensitive. Even a slight deviation from the standard settings would cause everything to grind to a halt. So at first, the sheer complexity and sensitivity of the two latest additions to the robotic work-force admittedly gave Head of Pro-duction Hans Beck and his team a few sleepless nights. "But since then, my colleagues and I have got to know the system well, and are interacting with it – that's a really important point." Automation does not mean rendering a human workforce obsolete – quite the opposite, in fact.

The new welding robot at the Vaduz plant covers the night shift, giving a helping hand to the human workforce.


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A large, sturdy, plate-shaped burner is at the heart of the Hoval BioLyt (8-36).

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The successful BioLyt family has a new member.Using technology-driven solutions to achieve sophisticated results: it's an approach that has Hoval written all over it. And it's one that has been successful for the latest addition to the Hoval family too: the biomass boiler.

Winning technology

A large, sturdy, plate-shaped burner is at the heart of the Hoval BioLyt (8-36). This ensures stability in the firebed. A new addition to it is the afterburner ring, which is installed above the burner plate. This innovative duo burns wood pellets and leaves hardly any ash behind in the process – a huge benefit for the environment.

The specially developed dust collector above the afterburner ring keeps dust emissions to a minimum: it swirls the combus-tion gases like a cyclone so that the heavier dust particles drop and cannot penetrate the chamber. The result is dust levels that fall far below European limits.

The BioLyt (8-36) features a microprocessor-controlled com-bustion regulation system which, thanks to its proven Hoval lambda probe, ensures that combustion takes place with maximum efficiency and guarantees trouble-free operation, even if pellet quality is inconsistent. This reduces pellet con-sumption, saves money, and is kind to the environment. High-efficiency regulators integrated into the heat exchanger facilitate the transmission of heat from combustion flue gases to heating water.

Because all the components involved in the combustion process work in perfect harmony, they enable efficiency levels as high as 98% to be achieved.

But it is not only these environmental credentials and effi-ciency that make the BioLyt (8-36) a winner: its safety aspects do too. The integrated burner rotary gate valve fea-turing a metering screw provides protection against backburn in the pellet storage area. Once rotating in the rotary gate valve, the pellets are fed through seven gates, transporting them from the storage container to the burner.

Easy installation and assembly

With the new BioLyt, Hoval has also responded to a major customer demand: the boiler body, trim and controller are delivered separately and assembled on site. This modular structure allows the BioLyt (8-36) to be installed even in cases where space is at a premium – in older buildings, for example. Additionally, the structure has made thermal dis-charge safety devices, cold water inlet pipes and wastewater disposal lines a thing of the past. Instead, the equipment comes with integrated low temperature protection as stand-ard, which enables it to be incorporated into practically any heat distribution system with ease. Combined with a solar installation, it satisfies maximum environmental standards. The entire system, including Hoval's own automatic firing devices, can be controlled centrally using the Hoval Top-Tronic® T controller.

The new Hoval BioLyt (8-36) wood pellet boiler achieves efficiency levels of up to 98%, while its output can be modulated continuously between 30 and 100%. It is the perfect choice for small to medium-sized properties as well as schools and commercial buildings. With its outstanding environmental credentials and user-friendliness, this baby of the family makes an impressive case for carbon-neutral heating using the domestic energy source of wood.


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Pellets – compressed bundles of energy

Wood pellets are made of 100% untreated wood. The raw material used for their manufacture is obtained from waste products such as saw dust and shavings from the wood pro-cessing industry. The raw material is compressed into small cylinders under high pressure without the addition of binding agents. The lignin contained in the wood serves as a natural binding agent for greater firmness.Two kilograms of pellets generate the same heat energy as 1 litre of heating oil. A year's supply can be stored economi-cally in a fabric silo or a pellet storage facility. The pellets are delivered by the supplier in sacks or in special tankers.

The large ash container is a clean solution that is easy to remove and empty.

With its output spectrum of 8 to 36 kW, the new BioLyt (8-36) offers a much wider range than its predecessor, the BioLyt (10-26). Not only that, but it is even closing the gap on its big brother, the BioLyt (50-160).

Home-grown, renewable, carbon-neutral

Wood as a source of fuel offers unbeatable advantages when it comes to environmentally responsible heating:▪ Wood grows right outside our door and thus considerably

minimises the effort involved in obtaining and transporting other energy sources.

▪ Wood is sustainable because it regrows.▪ Wood is also carbon-neutral: during combustion, only as

much carbon dioxide is released as was bound up by the tree through photosynthesis as it grew.

An economical and reliable energy source

As a domestic fuel, wood is safer from speculation on interna-tional raw material markets when compared with oil and gas. This guarantees relative price stability.Wood is also considered a reliable long-term, crisis-proof domestic energy source.

Clean and easy to use

Because the system produces so little ash, this means hardly any time spent disposing of it: generally speaking, the ash container only needs to be emptied once a year. And when a Hoval service technician comes to carry out the system's annual inspection, they may even be able to include this job too, depending on what the maintenance contract covers.


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In detail

Let's look at what happens in today's conventional production halls. Pipelines are routed from machines to a central system where extract air is cleaned. This air is then removed from the room via the roof and the heat it contains dis-appears along with it. A central ventila-tion system uses a second, separate pipeline network for supply and extract air handling in the hall. Heat is recov-ered from the room air – that is, if it is recovered at all. This whole system devours countless quantities of energy and demands a great deal of space – and let's not forget about the impurities that collect in the long pipelines. In short, the operating costs it involves are

Central extract air cleaning and ventilation system.

The extract air produced by metal-processing machines is contaminated with chippings, oil and cooling lubricants. Although extract air cleaning systems remove some of this, they do not eliminate it entirely, which is why the air is not usually fed back into the room. The heat energy that the extract air contains is lost as a result. Now, Hoval is bringing together the processes of extract air cleaning, heat recovery and room air conditioning to form its new ProcessLine system solution. This innovation reduces heating energy requirements by up to 98% when compared with systems that do not offer heat recovery.

ProcessLine – Hoval's system


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Quick off the mark

In Salzgitter, Germany, 6300 VW employees produce engines for not only VW itself, but also Audi, Bentley, Seat and Skoda. At VW, environmentally friendly production methods are a priority: the automotive company's management system has held Eco-Audit certification since 1996. So it's no surprise that in Salzgitter, VW has already switched to an energy-effi-cient solution from Hoval, and in one of its halls, where components for engines are manufactured, has installed six ProcessVent heat recovery and air condi-tioning systems in addition to its existing extract air cleaning system.

The international company Aesculap produces medical instruments and is based in Tuttlingen in southern Germany. Here too, environmental awareness has a big role to play. Since March of this year, two extract air cleaning systems, each providing an output of 5000 m3 per hour, have been cleaning machine extract air in a belt grinding machine area. A Hoval ProcessVent unit recovers the heat from the extract air, heats it and cools it – according to requirements.

high. Not only that, but they remain high even when only some of the machines are running, as centralised systems make it very difficult to carry out partial load operation efficiently.

Decentralised systems gaining ground

But here's how a modern production hall could look. Two compact units are positioned in the immediate vicinity of each individual machine group. One is responsible for extract air cleaning and the other for supplying fresh air, remov-ing extract air and, at the same time, recovering heat from the cleaned process extract air. The decentralised supply and removal pipes and ducts are routed directly to and from the units via the roof. This means considerably shorter distances when compared with the pipeline and duct network typical of a centralised system. Above all, this setup makes the best possible use of the synergies offered by the individual processes, as well as saving energy and money during operation.

solution for production halls.


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Saving energy on a grand scale

If the pollutant concentration is not allowed to exceed legally prescribed limits, the extract air from machine tools must be removed and cleaned. This machine extract air is warmer than the room air because the processing activities supply energy to it. Hoval ProcessLine doesn't just clean the process extract air – it also removes its heat and transfers the energy to the fresh air supply, cleanly and reli-ably.

This energy efficiency keeps con-sumption to an absolute minimum. Without heat recovery, one example of a hall in the German city of Stutt-gart would consume 81,095 kWh annually in order to control the temper-ature of the fresh air. A system that recovers heat from the room air would achieve savings of 73%. With its ability to recover heat from the process air, Hoval ProcessLine reduces energy consumption by as much as 98%, to 1690 kWh per year.

As a result, the Hoval ProcessLine system takes no more than three years to pay for itself. In just as short a time, the energy savings it achieves can amount to tens of thousands of euros.

81095kWh/a

-73 %

21557kWh/a

-98 %

1690kWh/a

Hoval ProcessClean filters and cleans

Hoval ProcessClean dry filters both coarser and finer dust to achieve a residual dust content that generally falls below 0.1 to 0.2 mg/m3. Hoval ProcessClean mix is able to sep-arate particles from production pro-cesses using dry and wet processing cycles. Hoval ProcessClean oil, mean-while, takes on the task of separating oil and emulsion mist. What makes this solution really special is that the degree of separation remains at a consistently high 99.9%.

Oil-proof heat recovery and room air conditioning using Hoval Process-Vent

Even after extract air cleaning, however, the air will still contain some oil or lubri-cant (albeit in miniscule quantities).

But for Hoval, this isn't a problem. "Our technology reliably traps and removes these remaining oil particles, provided they can be turned into condensation

during the subsequent heat recovery stage", explains Tobias Brugger, who heads up Hoval's production halls segment.

This technology represents a true Hoval innovation and is what makes the entire system possible: heat recovery with an oil-proof design is an unprecedented step forward. Its secret lies in the fact that the cross-flow plate heat exchanger as well as the entire extract air and exhaust air area are not only dirt-resistant, but also oil-proof.

Everything under control thanks to Hoval ProcessNet

Achieving perfect control over the Pro-cessClean and ProcessVent systems requires the ProcessNet control system. This user-friendly unit achieves maximum energy efficiency thanks mainly to its ability to link up the extract air cleaning and heat recovery features. Additionally, Hoval ProcessNet can be integrated into a higher-level building control system with ease.

Decentralised equals flexible

Together, Hoval ProcessClean, Pro-cessVent and ProcessNet work as a perfectly harmonised team in the form of the Hoval ProcessLine system solu-tion. And coupling this technology with Hoval's consulting expertise makes it possible to create solutions that are tai-lored precisely to the project in ques-tion. Tobias Brugger knows what cus-tomers demand in terms of flexible solutions: "The type of contamination and the production process determine the type of cleaning technology needed, and we combine this with heat recovery and room air conditioning technology to create a complete, customised solu-tion.".

Hoval is even extending this solution-oriented holistic approach to allow the new Hoval ProcessLine to be combined with the Hoval RoofVent® and TopVent® roof ventilation units. The latter is particularly suitable for handling supply and extract air in assembly areas as well as providing recirculation heating and cooling in storage and logistic areas. "The new system solution can even be extended to include a Hoval UltraGas® condens-ing boiler", says Tobias Brugger, who is full of enthusiasm for Hoval's joined-up idea.

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The Eidgenössische Mate-rialprüfungs- und Vesuch-sanstalt für Industrie, Bau-wesen und Gewerbe (Swiss

Federal Materials Testing and Experimentation Insti-tute for Industry, Construction and Commercial Buildings) in Zurich confirmed in a test

report from 1943 that the firing efficiency of the Hoval stove was cost-effective. The text in the brochure included testimoni-als by Hoval stove owners in

Switzerland and Liechtenstein who were very pleased with the units. Among the advantages of the Hoval stove was the fact that the cooking and heating processes

could be regulated individually, thus making it possible to save on large quantities of fuel. Even at that time it was a family operation, since the

woman in the picture is Maly, the wife of Hoval founder Gustav Ospelt.

Energy efficiency became very important to Hoval as early as 1944. Brochure for a central heating stove from 1944 or 1945 from the company Heizapparatebau Ospelt, Vaduz, Liechtenstein. company Heizapparatebau Ospelt, Vaduz, Liechtenstein.

The Eidgenössische Mate-rialprüfungs- und Vesuch-sanstalt für Industrie, Bau-wesen und Gewerbe (Swiss

Federal Materials Testing and Experimentation Insti-tute for Industry, Construction and Commercial Buildings) in Zurich confirmed in a test

report from 1943 that the firing efficiency of the Hoval stove was cost-effective. The text in the brochure included testimoni-als by Hoval stove owners in

Switzerland and Liechtenstein who were very pleased with the units. Among the advantages of the Hoval stove was the fact that the cooking and heating processes

could be regulated individually, thus making it possible to save on large quantities of fuel. Even at that time it was a family operation, since the

woman in the picture is Maly, the wife of Hoval founder Gustav Ospelt.

company Heizapparatebau Ospelt, Vaduz, Liechtenstein.

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Hoval AktiengesellschaftAustrasse 709490 Vaduz, Liechtensteinwww.hoval.com

Legal"Insights" – the Hoval Group magazine for customers and employees. Appears biannually at varying times.Responsible office: Marketing Services, Hoval Aktiengesellschaft, 9490 Vaduz, Liechtenstein.

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