kuehlen mit system en 24.09 - german pavilion · double circuit cooling plant in split design: ......

Perfect cooling

ChillerCentralised cooling plantsEnergy management

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For over 40 years Gesellschaft Wärme

Kältetechnik mbH has been manufacturing high-quality temperature control and cooling equipment and supplying this equipment worldwide.

Today more than 300 employees design, produce and install complete process solu-tions for heating and cooling in customer specific designs.

More than 30 sales and service locations worldwide represent the global character of our work and guarantee our permanent suc-cess.

In addition to a huge product range of serial products we also offer tailor-made solutions for challenging applications. These individually designed units are avail-able for a temperature range between –100°C and +400°C, and are developed and produced in Kierspe according to the customers’ demands.

As one-stop manufacturer of compact units, cooling plants and temperature control units, up to water treatment and heat recovery systems and complete container systems, gwk is a competent and innovative partner.

For over 40 years – Perfect cooling and temperature control

Headquarters in Kierspe, Germany

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Headquarters in Kierspe, Germany

3Perfect cooling www.gwk.com

Expertise in cooling plants

gwk units are essential all over the world. They are used by the plastics industry in Europe, international automotive groups or world- renowned sweets manufacturers, for cooling of metal processing and in chemical plants worldwide. The high reputation of gwk is owed to units being individually designed and built for specific customer re-quirements.

One of gwk’s production halls

U-bundle heat exchanger

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Without exception, all industrial manufactur-ing processes involve the in- and output of energy, which has to be supplied or taken away in the form of heat. The heat energy to be released is given off into the environment in the form of heat by the use of cooling plants. Heat recovery systems allow the heat to be converted into heat energy. Optimised combined systems minimise the energy con-sumption of the cooling plants and utilise energy by means of heat recovery at the same time.

The adjacent schematic diagram shows that cold water can be produced by several cooling systems, that clearly differ with view to investigation and operation costs. De-pending on the application the most suit-able cooling system can be chosen. Primarily the expected operating costs have to be taken into consideration.

Energy efficiency for the optimum cooling plant

gwk follows the principle that the optimum cooling plant for the specific application can only be found by analysis. This analysis is included in our expertise in energy effi-ciency and is used as a primary factor for a decision on the investment.

Minimising costs through energy effi ciency

Warehouse fl oorheating system

Heating unit

Heat

Energy Recycling


In most cases only a combined system can offer the best solution, i.e. a centrally con-trolled combination of different cooling units in connection with heat recovery, ca-pacity control of chillers and relief of the primary heating.

With its unique product range, gwk plans combined systems with lowest operating costs for production. That means to you, that gwk provides the complete guarantee for correct calculation and planning and installs its systems on a turnkey basis.

gwk produces combined systems and heat recovery sytems for more than 40 years now. Not only do the systems installed to date save several hundred million kilowatts of heating energy, they also save a similar quantity of electrical energy – hereby the amount saved is even larger due to the re-duced operating costs. Apart from the ad-vantage for the operator, gwk also renders an extraordinary contribution to protect the environment.

Energy flow diagram – optimised cooling of a production process

Production

Central cooling plant30/35°C

Central cooling plant10/15°C Industrial

manufacturing processes

Air compressor water cooled

Emergency heating with electrical heater

Venting unitHeating / Cooling

Offi ces,fl oor heating systemor hot water

Cooling ceiling

recovery from the heating condenser of the chiller

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gwk project study – optimising energy consumption

For minimal operating costs:

• Calculation of the optimised combined systems (cooling and heating systems) for injection moulding factories

• Exceeding the heat from the production machines under consideration of

– the best process reliability – high product quality – shortest cycle time

Selection criteria:

• Production plant and products= cooling power requirement

= lowest necessary water temperature

• Economic efficiency of the cooling plant= operating costs

• Energy management of the total production= potential of heat recovery

gwk-cooling plants for free

Project StudyPerfect Cooling and

Temperature Control

Gesellschaft Wärme

Kältetechnik mbH

Friedrich-Ebert-Str. 306D - 58566 Kierspe

Tel. +49 2359 665-0Fax +49 2359 665-156

[email protected]

Customer: Company Mustermann

Project: Replacement

Cooling Capacity: 200 kW

Quotation No.: 923xxx

In this project study the following cooling systems

have been compared:

– chiller with refrigerant R22 available on site

– new chiller with refrigerant R134a in split-design

and hermeticool-functiongwk uses outdoor temperature to reduce the operating costs

Influence of the cold water temperature

15 16 17 18 19 20 21Cooling water inlet temperature [C°]

25.000 ¤

20.000 ¤

15.000 ¤

10.000 ¤

5.000 ¤

0 ¤

Operating costs at inlet temperature

9000

8500

8000

7500

7000

6500

6000

5500

5000

4500

4000

3500

3000

2500

2000

1500

1000

500

0-29 -24 -19 -14 -9 -4 0 5 10 15 20 25 30 35 40

Outdoor temperature [C°]

hour

s /

year

Basic dataDN 4710 – meteorologic datato calculate the energy consumptionheating and air conditioning systems

Berlin 0 - 24 h Berlin 7 - 18 h

This is an unconditional promise. A gwk cooling plant can be acquired at no cost. The rea-son is that the investment costs for a new plant are amortised by the saved operating costs. Capital-free plant leasing makes plant contracting with liquid funds possible. (This offer is valid for Germany and the countries of the European Union).

By means of a detailed project study gwk calculates the most efficient and cost-saving solution


Project study example 1:Single circuit cooling plant with an process temperature about 15°C for the mould cooling and

hydraulic cooling at 235 kW cooling capacity.

Before optimization:

Single-circuit cooing plant with conventional chiller

After optimization:

Energy optimised single-circuit cooling plant with hermeticool

• Freecooling up to approx. 5,200 h/a

• Energy savings up to 240,628 kWh/a = 48 %

• Energy cost savings up to 20,167 ‡

• CO2-savings up to 168,440 kg

Industrial compact cooling plant with hermeticool

Project study example 2:Double circuit cooling plant in split design: Mould circuit 15°C with 87 kW cooling capacity and

hydraulic circuit 30°C with 148 kW cooling capacity

Before optimization:

Conventional design: mould circuit with chiller/ Hydraulic circuit with cooling tower

After optimization:

Innovative design: mould circuit with chiller and hermeticool / hydraulic circuit with hermeticool hybrid

• Energy savings up to 237,608 kWh/a = 46 %

• Energy cost savings up to 18,510 ‡

• CO2-savings up to 166,115 kg

• Savings of 1,800 m3 water per year

Mould circuit: air-cooled chiller with hermeticool

Hydraulic circuit: hermeticool hybrid

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The gwk project team consists of cooling and control specialists as well as engineers in process technology who have many years of experience at production level. This expe-rience leads to the high technical standard in centralised gwk cooling plants and com-bined systems. The water chiller is the most important module in a centralised cooling plant. But only the optimal dimensioning of all compo-nents leads to a perfect function. There are many options in the choice of the system. gwk prefers a closed circuit, with tanks made of stainless steel or plastic, with manifolds made from stainless steel and with factory piping made of PVC or PE. In order to reduce costs, we recommend a combination of several cooling systems to be controlled by a central computer and the gwk Software Central Energy Management System.

The centralised cooling plant

Quality is our strongest argument

As a rule, a central cooling plant is respon-sible for the overall production operation. Our gwk engineers therefore emphasize on correct dimensioning when designing a cooling plant for a production. This, in com-bination with the use of high-quality, long-life and maintenance-friendly components will achieve the highest possible reliability of the plant. A combined system exactly tailored to a specific operation will achieve the required reduction of operating costs by means of the lowest possible energy con-sumption.

Central cooling plant with water treatment


Electrical cabinet

gwk engineers plan and design complete control boards under consideration of spe-cific requirements and site standards. These systems are built by our qualified personnel and afterwards installed on site. The product range covers small operator panels, simple control cabinets up to large control systems.

Process visualisation

During industrial processes a number of individual parameters have to be measured and calculated. They include physical para-meters such as temperature, pressure, flow rate and power consumption. The following data is visualised by the gwk control system:• Operation parameters such as tempera-

ture, flow rate and pressure, power sup-plied to the production, operation hours of components and power consumption. The recording and processing of these data allows a centralised energy management.

• Storage of measuring data.• Indication of stored data by characteristics

or tables.

As a matter of fact communication with a superior network is also possible. The gwk process visualisation is based on the WinCC software system by Siemens, adjusted to the gwk unit systems which thereby allow an individual screen design.

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SKL and SKL C –gwk-energy-saving module

Water cooled chillers for industrial use

Energy-saving industrial water chillers have the task of drawing off heat from a process. This is done by targeted cooling with cold water at suitable points so as to simulta-neously increase production and improve quality.

Except for the low-temperature range, gwk chillers are operated with R 134a, a chlorine-free refrigerant. By choosing this refrigerant, the pressure conditions in the cooling circuit are clearly lower than in sys-tems that use other products.

gwk-energy-saving module

Energy consumption at a production period of 7,200 h/a:

Conventional solution: 317,355 kWhgwk-energy-saving-module: 216,865 kWhEnergy-saving potential: 31.7 %averaged COP-value with energy saving module: 5.15

With hermeticool-function (combined unit):

Conventional solution: 86,374 kWhgwk-energy-saving-module: 60,177 kWh

230

220

210

200

190

180

170

160

150

140

130

7,50

7,00

6,50

6,00

5,50

5,00

4,50

4,00

3,50

3,00

2,505 10 15 20 25 30

Outdoor temperature in °C

Capa

city

in k

W

COP-

valu

e

Conventional cooling capacity Cooling capacity R 134a with gwk energy-saving-module COP-value conventional compressor COP-value compressor R 134a with gwk energy-saving-module


As a result, the installed components are exposed to less stress, clearly less wear and the COP value is higher. Higher COP values mean lower operating costs.

gwk chillers of the SKL series are cold water aggregates with externally set-up condensers. These chillers are equipped with screw condensers; the power regula-tion of the capacity to be dissipated is continuous. Since shell and tube evapora-tors manufactured by gwk are used, these machines are especially suitable for indus-trial cooling processes. The gwk energy- saving module, in combination with an elec-tronic expansion valve allows realization of a continuous condenser regulation. With this type of operation, the ongoing oper-ating costs are reduced by approx. 25% compared to common cooling units.

Water-cooled cooling units by gwk are pref-erably used when cooling water at a higher temperature level is inexpensively available. With correct dimensioning of exchanger sur-faces on evaporators and condensers, the output figures of the machines are further optimised.

gwk-energy-saving module

Use of electronic expansion

valves reduces operating costs.

Advantages:• Fast reaction time• Even overheating regulation• Variable implementation

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gwk-cooling tower in use around the world

gwk cooling towers are used to carry off heat from production plants with higher temperature levels and work acc. to the principle of evaporation. Cooling towers are a part of a central cooling plant supplied on a turnkey basis which can be controlled by a fully programmable microprocessor.

To prevent pollution of the consumer by contaminated water from the cooling tower circuit, the cooling circuits of consumers and cooling tower are separated by an in-stalled plate heat exchanger. As a rule, wa-ter treatment and water purification are part of our supply and service program.


The GVK series of all-plastic cooling towers

Covering a range of capacities from 50 kW to 1200 kW, gwk all-plastic cooling towers resist the most extreme climatic conditions, because all the parts are produced from durable plastics. The interior parts are pro-duced from high-quality, high-impact plas-tics and are integrated into a housing made of glass-fibre reinforced plastic. Axial fans with pole-changing motors are matched to the capacity and operate at a reduced noise level. In addition, sound absorbers are op-tionally available in case of special require-ments for noise emission.

The gwk stainless steel cooling tower of the GHKV series

The cooling tower pack is made from a plas-tic honeycomb structure with a high heat exchange capacity and high mechanical loading capacity. The housing is constructed from stainless steel, forming a completely installed unit together with the water basin. Low pressure high capacity fans with a high level of efficiency and a low noise level force the cooling air through the fill-pack. Water return from the process is distributed equally by polypropylene hollow cone spray nozzles.

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KU-plant as closed cooling circuit for industrial cooling with direct connection to the pump and tank group of a cooling tower

KU-plant as closed cooling circuit for industr cooling with direct connection to the pump and group of a cooling tower

Clean process water with gwk KU-plants

Cooling tower water loaded with concentrated solids and particles should not be passed through the cooling channels of production machines. Here too, gwk KU-plants provide clean working.A microprocessor controller working in com-bination with a continuously operating mo-torised valve provides precise temperature management regardless of the temperature of the fresh water available. Consumption of fresh water is minimised and expensive water treatment is not required. The operating pump works continuously at the same pressure and thus ensures con-sistent flow conditions. Automatic water feeding prevents the water level dropping too low. Providing a standby pump that is switched in automatically and also emer-gency cooling via the fresh water feed in-creases safety in operation.KU-plants are an ideal tool to reduce mainte-nance costs, since all the production ma-chines remain clean and ready for operation.

Water is an excellent cooling medium. KU-plants from gwk utilise the cooling energy provided by water to carry away heat from production machines in the most trouble-free and cost effective way possible.Fresh water from a well, from rivers and from other surface reservoirs is always saturated with oxygen and includes a large number of minerals and suspended particles which can block up the cooling channels in production units through corrosion or by producing de-posits.KU-plants from gwk do not allow such prob-lems to arise. A plate-type heat exchanger made of stainless steel separates the clean closed circuit that is used to cool the produc-tion from the natural fresh water circuit that is contaminated with all kinds of impurities.


The use of KU-plants provides a closed cooling circuit and reduces maintenance costs

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Energy saving hermeticool cooling plants

Douple-circuit cooling plant with energy saving hermeticool-technology

hermeticool units can be used wherever the cooling water temperature is at least 5K above air temperature. The function of the system hermeticool is to transport heated water to the external free cooler where the heat is transferred to the ambient air by means of direct heat exchange.

Common free coolers must be filled and op-erated with a water-glycol mixture in order to prevent freezing in case of a plant stand-still in winter. In order to not contaminate the consumers with glycol and thus limiting heat transfer, a heat exchanger must be in-stalled to separate the circuits. This is not necessary when using gwk hermeticool units, which are operated all year without glycol. Constructive details and an integrat-ed safety system prevent freezing even with-out additional heating. Compared to glycol operated free coolers this system achieves considerable savings in operating costs.


gwk-hermeticool hybrid

• works in a closed cooling water circuit• functions cleanly, maintenance-free and without water loss

• is the ideal replacement for open evaporation cooling towers and prevents disadvantages of pollution, salt and oxygen enrichment

• works according to the air cooling principle

• lowers the temperature of the cooling air down to dew point

• this type of system provides cooling water of a temperature below outside temperature

• is available at power levels of 50 kW to 6 MW nominal cooling capacity

Free cooling with hermeticool hybrid

gwk-freecooler are space saving and energy efficient cooling systems. The hermeticool hybrid circuit, often known as adiabatic freecooler, is a closed circuit cooling sys-tem. The position of the unit is usually on the roof of the production building. At low night temperature the hermeticool is most efficient. The integrated hybrid function al-so permits the reliable function at high day time temperatures.

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Tailor-made compact chillers for special production processes

Chillers need to be adapted to the specific requirements of the application to ensure an exact temperature regulation and a reliable operation.

Explosion-proofcompact chillers

In many processes simple cooling with in-dustrial water is not adequate. Individual process-controlled temperature manage-ment requires the use of chillers directly in the production plant, especially if materials that are a fire hazard are being produced or processed. Explosion proofed chillers are offered as standard by gwk and can be equipped with a wide variety of options.

Chiller in Ex-design


Low temperature chillers

In chemical processes reactions are initiat-ed and monitored according to temperature and pressure. Using a wide variety of ma-chine components, chillers can be pro-duced in modular form with one or more temperature circuits over a total tempera-ture range from -60°C up to +220°C. Machines of this type basically have micro-processor controllers which regulate the timing sequence and the temperature of the process. We recommend discussions with our process engineers to ensure cor-rect sizing.

Explosion-proof chillers for the Ex-zones 1 and 2 are part of the gwk standard range

Compact chiller with two individually controllable cooling circuits

Low temperature chiller with integrated heating circuit

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gwk-energy recycling and heat recovery

gwk-energy recycling

Every industrial production requires energy in order to make products. Often, electrical or primary energy is induced as heat, used for operation and must then be dissipated, converted or destroyed.

Our gwk process engineers analyse and calculate production processes and the overall thermal periphery with the objective of lowering the necessary energy by means of energy recycling, of reducing the energy requirement at the individual stations, of converting energy or using it several times and dissipating it sensibly.

The result is considerable energy saving, which results in cost-cutting and contributes to preserving the environment.

gwk-heat pumps

Heat pumps are cooling machines which are primarily regulated by the cold water temperature and are mainly used to draw off heat from production units. In winter this heat is pumped to a higher temperature through the compressor and made usable for heating purposes. In the summer the heat is drawn off into the outside air by means of externally-located condensers. gwk heat pumps are filled with R 134a re-frigerant and can produce hot water of temperatures of up to 60°C.

In order to heat service water all year round, a desuperheater is placed before the heat-ing condenser to heat the service water up to a maximum of 70°C. Desuperheaters are an extremely useful option for each water chiller. Heat pumps in combination with air extraction and ventilation units can

be used in summer to provide cooling by extracting the heat from large rooms and halls to provide cold air at specific points to cool production equipment such as blown film units, and to support the hall heating in winter by passing hot air directly from the heating condenser into the air ducts.


The use of gwk-air heaters means that the heat from production machines

provides heating energy at no cost.

gwk-heat pumps have the task of cooling production machines and saving heating energy. They help the environment and reduce annual operating costs for their users.

gwk-air heaters

gwk-air heaters consist of copper tubes with metal fins which give off the heat from production machines into the circulated am-bient air. These aggregates convert heat en-ergy without utilizing additional primary en-ergy. In a direct circuit the heat produced in the process is pumped directly to the air heater, for example the heat given off by a hydraulic circuit.

By comparison, in an indirect circuit the heat is given off first by a heat exchanger into the heat transfer medium in the heat exchanger circuit. This is in principle much the same as in a central heating system.

gwk-air heaters are of two types: of open construction with an axial fan for the heat-ing of large rooms and halls, and a more presentable form with a nice housing and a radial fan for use in office or apartment.

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A complete centralised cooling plant, includ-ing the required peripherals, can be set up in the absolute shortest possible time at the subsequent place of installation and is im-mediately ready for use by means of prefab-rication and installation in a container. This way, the otherwise high investments for an operating building, the costs for installation and start-up of the plant are reduced.

Container cooling plants almost have no limi-tations in terms of their capacity and variety of possible combinations. They are supple-mented by peripheral systems such as water treatment and water preparation systems or compressed air compressors. If the produc-tion operations are re-located, then the con-tainer can be moved as well without any dif-ficulty. Generally it is not necessary to obtain a special construction permit.

The decisive factor for the selection of a container cooling system are of course the future operating costs. A series of different cooling systems and the combined systems composed of these units are primarily avail-able:• Chiller • Heat pump systems for heat recovery• Cooling tower combined with a KU system

as a closed, clean cooling circuit• Air heaters for direct recovery of heat• hermeticool-units• hermeticool hybrid-units

Centralised cooling plants in containers save space and money

Containerised cooling plants are designed acc. to

the individual demands

A containerised cooling plant can be set up in the absolute shortest possible time and is im-mediately ready for use

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All containers for installation of the cooling plants are tailor made, tuned to specific needs and requirements. The walls are insulated in terms of sound and heat; openings for pipe connections and electri-cal supply are provided.

The roof of the container is prepared to re-ceive exterior aggregates. Since container cooling systems are set up outside, they do not cause building costs or result in los-ing valuable production space.

Containerised pump and tank group

Perfect cooling www.gwk.com

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Clean water is also part of it

Due to its good heat transfer properties and high specific heat, water is extremely suitable as a heat transfer medium. On the other hand, a large number of substances is dis-solved in water and this can cause unwant-ed side-effects in a cooling system, such as deposits. Water can take up and release oxygen and thereby cause corrosion. We want you to use only water that will cause you no problems. Our laboratory will pre-pare an analysis based on a sample of wa-ter. The water analysis is the basis of a rec-ommendation for the water preparation required and to determine how the water should be treated.

Water preparation means in every case the production of treated water which is suitable for use in cooling units. In this connection water softening units of different sizes are applied.

For maintenance of the water we recom-mend our after-sales service and the com-pletely automatic water treatment, type active. We can deliver test equipment, cleaning equipment and the necessary chemicals for your own maintenance per-sonnel.

Double water softening unit to remove the minerals that form lime scale and dosing station for inhibitors to prevent corrosion, integrated into a container unit

Perfect cooling www.gwk.com25

Infrared image of an injection mould.

Left: Inhomogeneous increase of temperature due to the use of con-taminated heating/cooling channels

Right: Homogeneous temperature distribution after flushing the mould and conditioning the water

gwk active-mk 100-2: compact system for cleaning and conditioning of cooling

water for dual-circuit cooling systems

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One-stop turnkey plants

Our tasks include the complete planning of a cooling plant including all the peripheral equipment and instruments. Above all, the planning of the entire piping system for a specific and consistent supply of all con-sumers rounds off our package of services.

On request we can produce for you complete layouts for cooling water, material supply, power supply and compressed air lines. Our installation teams are experienced in the lay-ing of piping systems made of steel, copper, stainless steel, PVC, polyethylene and poly-propylene. On the basis of our detailed plans you can also have the work carried out by in-stallation companies which you prefer.

The connection between the cooling plant, heat recovery system and the existing heat-ing unit is made through hydraulic switching systems. gwk makes use of all current seri-al and analogue interfaces for data transfer between the production machines and the cooling system or the cooling system and the heating unit or to communicate with a process controller.

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gwk-service – worldwide and round-the-clock

...Increase of process reliability

Increasing product quality requirements and reduction of downtime in future- oriented manufacturing plants make maintenance most essential to avoid un-scheduled standstills.

...Increase of warranty

Warranty periods of new units can be indi-vidually extended by means of service contracts.

...Increase of productivity

This includes adjustment of parameters to improve production processes as well as the exchange of spare and wear parts. The equipment of our service engineers allow to immediately carry out cleaning of water circuits.

...Make life easier for maintenance

We ensure this with our service contracts.

With gwk-service...


Retrofit refrigerant R 22

Acc. to EG regulation: 2037/2000• it is not allowed to use new refrigerant

(R22) for maintenance or repair starting from Jan 1, 2010.

• it is no longer allowed to operate cooling plants filled with R22 from Jan 1, 2015.

Many cooling plants can be retrofitted to

an alternative refrigerant.

Our Services:• Plant evaluation• Retrofit to alternative refrigerant• Commissioning

Reduction of the greenhouse-effect

It is based on the EU regulation 842/2006.

The objective is to reduce the greenhouse effect, which is caused by refrigerant that has escaped from cooling plants.

Since July 4, 2007 all cooling equipment needs to be checked regularly, depending on the amount of refrigerant.

The number of leakage tests may be reduced down to one test per year when suitable leak-age monitoring systems are installed.

Our Services:

• Leakage test on T & M basis• Maintenance contract including leakage

test• Test book and certificate

nt g

g

o

Project planning

• Infrared analysis• Performance measurement• Project studies• Mould dimensioning

Contracting

• Used machines• Contracts• Financing

Support

• Maintenance• In-house service inspection• Teleservice• Mould cleaning / system cleaning• Training• Spare parts

Optimization

• Retrofi tting / redesigning• Advice / support• Water analysis

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References

Increased productivity

In many areas of the industry, cooling and temperature centrol provides a great potential for increasing productivity and thus for lowering costs.

• Reduction of cooling time, therefore savings in required machine hours

• Improvement of product quality

• Increasing availability of production plants• Decreasing running cost• Reduction of maintenance cost

Many factors serve to improve productivity:

Production

costs

Cost

reduction

Perfect cooling and temperature control

gwk-KU-plants

The simplest and cheapest solution to increase the availability and to decrease the maintenance cost of open cooling systems.

gwk-HSW

Cost reduction by means of ad-vanced heat recovery systems.

gwk-weco

Controllable production in variable climatic conditions and high flexibility with com-pact, energy saving water chillers using environmentally friendly refrigerant.

gwk-container-plans

Highest flexibility and lowest expenses for planning in-stallation and movement of a centralised cooling plant.

gwk-active

Adjusting and maintaining optimum capacity by means of constantly clean water, delivered from a fully automatic water treatment device.

gwk-service

Decreasing the maintenance cost and protection of company owned resources through professional installation and service including maintenance of cooling water.

Gesellschaft Wärme Kältetechnik mbHFriedrich-Ebert-Straße 306 · D-58566 KierspeTel. +49 2359 665-0 · Fax +49 2359 [email protected] · www.gwk.com

KA.

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gwk-teco cw

Most economic system to extract heat from consumers at very low temperatures by patented cold water tempera-ture control.

gwk-hermeticool hybrid

Innovative cooling system to decrease the running and main-tenance cost in comparison to conventional cooling systems.

gwk-tecma

High process stability with customised temperature control solutions for all appli-cations with high performance requirements up to 400°C.

gwk-SKL/SKW

Reliable and economic supply of cooling water in the low temperature range, even under the toughest ambient conditions.

Preliminary Report K 2010

gwk Focuses on Energy Efficiency, Part Quality and Process SafetyOn the occasion of this year’s K 2010 exhibition

in Düsseldorf (27.10.-03.11.2010), gwk Gesell-

schaft Wärme Kältetechnik mbH, Kierspe, focuses

all its energy on the topic energy efficiency and

presents innovations in cooling and tempera-

ture control at its stand J 39 – that is enormous-

ly extended compared with K 2007 - in hall 10.

In the centre of customer’s attention are still sy-

stem solutions regarding saving of energy co-

sts and optimisation of applications in plastic

processing by means of innovative tempera-

ture control systems. Particularly increasing

costs and competitive pressure are more and

more a burning issue that forces the plastic pro-

cessor to increase his activities in this subject.

gwk will not only show the complete range of

cooling and temperature control with actual

themes by means of static exhibits, but also

by presenting live injection moulding appli-

cations. In the focus of the customer’s atten-

tion is the production of high-quality surfaces by

means of dynamic cavity temperature control.

New Perspectives due to Dynamic Temperature

Control Systems

Within a common project, sponsored by BMBF with

partners in industry and science, that aims at de-

veloping efficient temperature control systems in

plastic processing, the status of development will

be presented on a 800-kN KraussMaffei injection

moulding machine with view to the prevention of

weld-lines on high gloss surfaces. In order to achieve

the required mould wall temperatures during in-

jection without major extension of cycle times, a

gwk Gesellschaft Wärme Kältetechnik mbH · Friedrich-Ebert-Str. 306 · 58566 KierspeTelefon: +49 23 59 - 66 50 · Telefax: +49 23 59 - 66 51 56 · eMail: [email protected]

mould, produced by Messrs. Krallmann, is executed

with ceramic power heaters.

Installed only a few millimetres behind the cavity,

they accelerate the heating process at a minimal

energy consumption rate at the same time. Heating

rates up to 25 K/sec are achieved, at a heat flux

density of 150 W/cm², with the tenth of the total

energy requirement of fluid heating systems. Directly

underneath the heater are the close-to-cavity

channels for the water cooling. As the thermal con-

ductivity of the special ceramic material is approxi-

mately two times higher than that of tool steel, the

cooling through the switched off heating is very ef-

fective. As temperature modifications without major

extensions of cycle times are possible, this system

is entitled to be called “dynamic cavity tempera-

ture control”. The complete temperature control in-

cluding water supply is effected by a temperature

system, type integrat evolution, that is connected

with the injection moulding machine via a VARAN-

bus and is communicating in a real time mode.

Apart from KraussMaffei and Krallmann, the Fach-

www.gwk.com

Dynamische FormnesttemperierungFür bindenahtfreie Hochglanzoberflächen

hochschule Rosenheim and the Fraunhofer-Institut

für Produktionstechnik und Automatisierung IPA,

Stuttgart, are partners of this development project.



the ceramic heaters in dependence on the cycle

while, during the following cooling phase, ano-

ther module supplies the cooling via proportional

valves. All control modules are installed vertical-

ly, one on top of the other in a common frame

that only requires 60 x 60 cm space. Data input

is effected via a central operating panel. All pro-

cess data are shown graphically and numeri-

cally on a touch-screen with coloured display.

Based on permanently increasing energy costs and

the demand for higher productivity, the dynamic

cavity temperature control system is an ideal ap-

proach to produce in future high-quality plastic

materials with complex demands in a

cost-effective way, too.

Famous Machine Manufacturers Integrate

Dynamic Cavity Control System

So, the dynamic temperature control system is

applied twice by KraussMaffei for their exhibition

highlights. With view to the cover-form procedure

for the scratch-proofed coating of PMMA parts, that

was developed together with Evonik, the dynamic

temperature control is responsible for the initiation

of the chemical reaction. By this, a reasonable inte-

gration of an expensive and until today succeeding

finishing process is possible. In a second applica-

tion, which presents the moulding and coating of

organo sheets for structural components in light-

weight construction in one step for the first time, the

gwk integrat evolution technology is used. Ceramic

heaters that are integrated in the mould and the

corresponding control technology take over an im-

portant function in the injection moulding process.

For its innovative adiabatic multi-component

procedure, that the IKV developed and presented

for the first time to the public on the occasion of

the cluster “Integrative Produktionstechnik für

www.gwk.com

Economic Production of High-quality Surfaces

Ceramic heaters for dynamic cavity temperature

control are also part of the second application. On

an Arburg injection moulding machine with vertical

clamping unit, the high-quality back injection moul-

ding of metal films is shown, that was developed in

cooperation with the IWK, Rapperswil/Swiss and

the Swiss mould manufacturer Georg Kaufmann.

Dynamische FormnesttemperierungAm Anwendungsbeispiel Hinterspritzen von Metallfolien

In this process the bonding agent of the metal

film is activated by means of integrated power

heaters before the plastic material is injected

into the mould. This leads to a homogeneous

connection between metal and plastic material,

stress-relieved with high dimensional stability and

a cycle time reduction by 40% at the same time.

The heating and cooling is effected by the opti-

mised multi-circuit temperature control system

integrat evolution. Several segmented tempera-

ture circuits control the basic temperature of the

mould body. An electric control module controls

Hochlohnländer” (integrative production techno-

logy for high-wage countries) the IKV as well applies

the gwk dynamic temperature control system. For

the production of heatable sports glasses with in-

tegrated metal conductors that were injected into

the plastic material, this mould was equipped with

the highly dynamic gwk integrat evolution techno-

logy as well. The processing of the metal compo-

nents in the second mould station is effected by

means of integrated ceramic power heaters that

are integrated in the mould insert in connection

with close-to-cavity temperature control channels.

The temperature control of the complete system

is effected by an integrat multi-circuit system.

The energetic and high-quality foaming process

presented by the machine manufacturer Teubert,

is also based on the cyclic, dynamic temperature

control in the mould. For this purpose gwk deve-

loped a 200°C version of the teco vario system,

consisting of a two-circuit hot water temperature

controller and a close-to-cavity energy storage and

switching unit subordinated to a central control

system that communicates with the machine’s

control system. A second system with identical

construction is presented on the gwk stand.

In addition to the dynamic cavity temperature con-

trol with fluid media, gwk also works on temperature

control systems with gaseous media. A demonstra-

tor presents the development status of a variotherm

CO2 -temperature control system, that for the first

time is heating and cooling with CO2 with minor en-

ergetic expenditures. Development partner of this

innovative temperature control concept is Linde

AG, Unterschleißheim as well as the ISK, Iserlohn.

Innovations With View to Standard Temperature

Control Systems

Apart from the development of innovative system



www.gwk.com

solutions gwk advanced the continuous ex-

pansion and modernisation of its range of

single temperature control units and ad-

apted those to the market requirements.

The teco cs-series that proofed a success has been

upgraded by a touch-screen with new, integrated

functions. The units in standard execution, too, are

now equipped with a flow meter and simultaneous

indication of its set and actual values on a coloured

display. The temperature profile is shown graphi-

cally according to the corresponding menu func-

tions. By means of touching symbols on the start

page, practical functions like limit comparator, leak

stop operation etc. can be selected . The teco

cs units can now be executed with the super

fast VARAN interface. To increase the opera-

tional safety a service page shows maintenance

intervals and advice in clear text indication.

teco cs-units are designed for the operation with

water as circulation medium and allow an use up

to 95ºC/140°C/160°C. The 95°C series has been

extended by three additional models with higher

capacities. The new, cost-effective models are de-

signed for larger consumers and dispose of heating

capacities from 18 to 36 kW, cooling capacities

from 50 to 120 kW and flow rates from 110 up to

170 l/min.

As some particular applications require tempe-

rature control units that are operated with oil as

circulation medium, gwk also revised the teco to

series up to 180°C as well as the teco tt series up

to 300°C in order to correspond to the customers’

requirements.

As far as the segmented cavity temperature con-

trol is concerned, gwk has taken the requirements

for higher mould temperatures into account. After

an extensive testing period, the successful multi-

circuit temperature control system integrat 40 is

also available in a 140°C execution now. The tem-

perature range of the flow meter control system in-

tegrat direct, in the past restricted to temperatures

under 100°C, has been extended to temperatures



www.gwk.com

teco cs Serie mit Touchscreen

of 120°C. According to the customers demands

the standard version has been completed by a

more reasonable basic version, which still allows

the control of the flow quantity in each circuit via

the interface compatible integrat process control

system with touch-screen operation, only the set-

ting and modification of the water quantity has to

be effected manually. By contrast, in case of the

more comfortable standard version, the requested

water quantity can be set and controlled automa-

tically via touch-screen or alternatively by means

of the set temperature difference between water

supply and return monitored and controlled by the

control system.

gwk Energy-Recycling

Besides the temperature control technology the

company will present the latest developments in

cost-reducing cooling technology at its stand under

the key word “gwk Energy-Recycling”. It will also be

represented at numerous stands of other compa-

nies that present innovative cooling and tempera-

ture control solutions.

Preliminary Report Cooling Technology K 2010

gwk increases the energy-efficiency of water chillers by 36 %

On the occasion of this year’s K 2010 exhibition in

Düsseldorf, gwk Gesellschaft Wärme Kältetechnik

mbH, Kierspe, focuses all its energy on the topic

energy efficiency and also presents in addition

to innovations in temperature control, highly effi-

cient water chillers and central cooling systems.

The company located in the Sauerland will not only

show the complete range of cooling and tempera-

ture control with actual themes by means of static

exhibits, but also by presenting highly topical live

injection moulding applications. Here the produc-

tion of high-quality products with lowest energy

input is in the focus of the customers’ attention.

New intelligent composite systems reduce the en-

ergy costs as well as the CO2-consumption

Trend in cooling technology is saving the utmost

operating costs in the cold water production and

use of waste heat for heating processes. The per-

manently increasing costs for fuel oil, gas and elec-

tric energy put the customer under pressure in a

way, that more and more de-mands are made how

many kilowatt hours have to be used for the pro-

cessing of one kilogram of plastic material. Those

boundary condi-tions can only be fulfilled by tailor-

made composite systems with integrated energy-

saving modules.

At the K 2010 gwk presents such a composite

system in connection with the two injection moul-

ding machines, that is capable of meeting all

process demands with view to the required tempe-

ratures and water quantities through a minimum

energy input at the same time. This means that

temperature controllers and water chillers are

operated in a neatly aligned energy composite


system. Of course, environmental aspects are

taken into consideration here as well. So, for more

than 15 years gwk has used the highly efficient

refrigerant R 134a, that is chlorine-free and has no

ozone depletion potential. The system pressures

that are low in comparison to other refrigerants,

reduce signs of wear and increase the working

life of the components in the refrigerant circuit.

Recalculated and technically modified evaporators

and condensers as well as energetically optimised

screw compressors with improved control concept

lead to another capacity improvement. So, the

maximum energy efficiency of the complete

system can be reached and a major contribution to

the reduction of CO2-emissions is made.

New energy-saving modules are efficient cost-

cutters

The hermeticool cooling system shown by gwk uses

the differences of night and day temperatures as

well as those of the seasons in order to produce

cold water for production facilities in a cost-effec-

tive manner. Here the running time of the energe-

tically cost-intensive water chiller is reduced to a

minimum. Sophisticated energy-saving modules to

control the refrigerant flow and motor speed in de-

pendence on the ambient temperature and load,

increase the efficiency by 36 % in comparison to

conventional systems. By means of the new gwk-

motor management the actual power consumption

of the fans is continuously monitored and adapted

to the capacity demands via speed control, so that

the lowest energy consumption is always attained.

These new motors with a high efficiency rate in

comparison to conventional technologies can be

operated with an extremely low rotational speed,

www.gwk.com

so that – in combination with the optional night-

time temperature reduction – a major decrease

of the sound level can be achieved. The individual

operating parameters of each motor can be stored



www.gwk.com

and in case of an eventually required motor ex-

change, be reintegrated in the comfortable motor

control system.

By means of different installations gwk shows, how

operating costs can be reduced by 75 % compared

with conventional cooling systems.

Energy-saving adiabatic function now integrated

in the new generation of compact water chillers

up to 1.200 kW nominal cooling capacity

With the presentation of a compact water-cooled

injection moulding machine with 180 kW nominal

cooling capacity, gwk shows - in addition to the

already mentioned modifications to increase the

energy efficiency - now as a premiere at the K

2010 the new adiabatic technology, that is known

for its maximum efficiency with a minimum water

consumption.

By means of the extremely fine atomization of

water in the suction area of the condensers, it is

possible to extend the scope of applica-tion for the

reasonable production of cold water through the

ambient air without expensive compressor energy.

This innovative energy-saving function as well as

the installation of the new high-capacity evaporator

are available as integrated option in the extended

SKLC-water chiller series (min. 100 kW, max.

1.200 kW nominal cooling capacity). In order to in-

crease the operational safety, the new water chil-

lers from 200 kW nominal cooling capacity upward

are equipped with two separate cooling circuits.

Integrated water treatment and use of waste

heat guarantee high productivity while saving

costs at the same time

The longterm efficiency of a temperature con-

trol and cooling system is guaranteed by a water

treatment system that is adapted to the process

temperatures and the materials used in the ma-

chine components that are in contact with water.

In the interest of short cycle times and low energy

input, the production of deposits that reduce the

heat transfer in the temperature control channels

is prevented by a central, compact water treatment

system. In such a central, completely functioning

cooling unit gwk presents the whole range of re-

quired components from latest filter technologies

via dosing of chemicals up to a unit for the clea-

ning of calcified temperature control channels.

For example gwk-energy recycling components

are demonstrated by using the return water of the

hydraulic cooling of the two injection moulding

machines for heating purposes via under floor

heating and heat exchangers.

Cost-efficient cooling in a gwk containerized

cooling system

The biggest exhibit at the gwk stand will be a cen-

tral cooling system for an injection moulding pro-

cess, that is completely integrated in a container.

In addition to the pumps and water collection tanks

for the outside mould cooling and the hydraulic



www.gwk.com

Beyond the presentations at its own stand, gwk

will be represented with innovative cooling and

temperature control concepts at a large number

of other stands like for example Arburg, Krauss-

Maffei, Sumitomo Demag and many more.

cooling installed on the roof of the container, this

exhibit with a length of 10 m will also contain the

equipment for cleaning and conditioning of the

cooling water. A visualisation system and the gwk

energy recycling components to connect a hall

heating system with heat exchangers complete

the containerized concept that will be applied 500

times worldwide.

kuehlen mit system en 24.09 - german pavilion · double circuit cooling plant in split design: ......

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