Energy efficiency in industry and production

Integrating energy-efficient cleaning processes into production

Case Study of BOSCH Diesel engines
Various cleaning processes are necessary during the production of components for diesel engines in order to ensure that the finished parts do not contain any chips or other debris. A company-wide analysis of Bosch has identified the cleaning of these parts as one of the most energy-intensive production processes.

10-20% of energy is saved by reducing bath temperatures

Diesel Systems alone operates approximately 700 major facilities throughout the world. Together with our location in Homburg, the central department for production engineering, and with machine manufacturers, we have been able to develop numerous improvements which are now being considered in new purchases. Furthermore, they are being partly adopted as a standard by the manufacturers. However, retrofitting is often economical for payback periods of under two years.

Standby at the component level
An adaptation to the control software allows individual components which would otherwise always be in use to switch off when they are not needed.

Temperature reduction
The temperatures of the cleaning media can be significantly lowered through practical experiments without altering the chemistry or the cleanliness of the products.

Isolating the containers, filters and pipes minimises heat loss.

Pump control
Larger pumps are especially used for high-pressure cleaning. The pressure is often constantly maintained by a lossy bypass regulator. The new regulation of the pump speed provides significant savings.

Realised savings
The retrofitting process in Homburg is almost completed and there has been average energy savings of 25%. In some cases, this can be up to 340 MWh per machine. Altogether, the location has reduced its consumption by over 8,000 MWh per year. We kicked off our global rollout in mid-2012, and to this point we have been able to account for total savings of about 21,000 MWh per year. This is equivalent to the electricity needs of 5,250 single-family houses.

contact details/company:
Robert Bosch GmbH
Diesel Systems
Wernerstr. 51
70469 Stuttgart-Feuerbach

contact person:
Steffen Behnke
+49 (0) 711 811-30379