1st prize: Energy Efficiency Award 2014.

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1 Photo: Susanne Dobler 1st prize: Energy Efficiency Award Aluminium Norf GmbH Process optimisation in the metal industry. As part of its Initiative EnergieEffizienz, the Deutsche-Energie-Agentur (dena) the German Energy Agency has awarded 1st prize in the international Energy Efficiency Award to Aluminium Norf GmbH. Run by dena with the support of its premium partners DZ BANK AG, Imtech Deutschland GmbH & Co. KG and Siemens AG, the competition is funded by the German Federal Ministry for Economic Affairs and Energy (BMWi) on the basis of a decision by the German Bundestag. Project description. Aluminium Norf GmbH pursued the goal of moving aluminium coils carrying the heat from the cold rolling process for further processing in furnaces without a loss in temperature. An approach contrary to the previous practice of cooling aluminium coils heated from the rolling process to below 60 degree Celsius and then, in aid of safer process conditions, heating them up again to an annealing temperature of 480 degree Celsius. To achieve this goal, the company established a plant concept never previously applied in industry and realised the large-scale use of an energyefficient annealing furnace plant with protective gas preheating and a primary control concept. The thermal state of each aluminium coil is computer controlled along with the energyefficient operation of the furnaces with individual burner zones. A temperature measuring concept utilises the individual burner control with a simultaneously reduced number of burners. Examples of energy efficiency measures implemented. Utilisation of the residual heat from the rolling process during annealing through the use of hot coils Protective gas preheating with the aid of exhaust gases Computerised control for each aluminium coil Equipping all fans and blowers with variable-speed drives Sealing and insulating the furnaces Figures for the energy efficiency measures implemented. 1 Energy costs Energy consumption CO 2 reduction thousand/year 2,000 1, ,500 million kwh/year thousand tonnes/year Energy savings in percent 45% energy consumption million kwh/year 1, , CO 2 reduction 3 energy costs Investment 4 8,434 t/year 835,000/year 7.6 million Return on investment 11% Before optimisation After optimisation Savings 1 For reasons of clarity, the figures are rounded off. 2 Assumed reference throughput of 180,000 t/year. 3 The calculation for natural gas (201.1 g CO 2 /kwh) and electricity ( g CO 2 /kwh) is based on the Global Emissions Model for integrated Systems (GEMIS). 4 Funded via the Environmental Innovation Programme of the Federal Ministry for the Environment, Nature Conservation, Building and Nuclear Safety (BMUB) to the amount of 1.5 million.

2 2nd prize: Energy Efficiency Award Moll Marzipan GmbH Optimising production processes in the food industry. As part of its Initiative EnergieEffizienz, the Deutsche-Energie-Agentur (dena) the German Energy Agency has awarded 2nd prize in the international Energy Efficiency Award to Moll Marzipan GmbH. Run by dena with the support of its premium partners DZ BANK AG, Imtech Deutschland GmbH & Co. KG and Siemens AG, the competition is funded by the German Federal Ministry for Economic Affairs and Energy (BMWi) on the basis of a decision by the German Bundestag. Project description. The food company Moll Marzipan GmbH implemented a package of measures aimed at demand-oriented energy optimisation at its production plants. Examples of the individual measures taken include the upgrading of the air volume control in an almond roasting line from a valve-controlled system to variable-speed operation. The cold water supply was also optimised by raising the target temperatures, integrating the external cooling and optimising the controls. Measures to increase energy efficiency were also undertaken in relation to production planning. For example, due to the increased dryer capacity, it is no longer necessary for products to undergo a subsequent drying process. With respect to the compressed air systems, the company focused both on technical factors, such as controlling the compressed air production, and on the employees in particular: Trainees, organised as compressed air police, continuously searched for and repaired compressed air leaks. An energy control system was introduced for documentation. Examples of energy efficiency measures implemented. Energy optimisation of air volume control in an almond roasting line and the cold water supply Introduction of continuous monitoring of the compressed air systems and control of compressed air production (trainees) Increased energy efficiency via optimised production planning the consumption of 100 C process water Figures for the energy efficiency measures implemented. 1 Energy costs thousand/year Energy consumption million kwh/year CO 2 reduction tonnes/year 1,100 1, , ,067 1,102 1, , ,000 2, ,500 2,000 Before optimisation After optimisation Savings Energy savings in percent 11% energy consumption 1.13 million kwh/year CO 2 reduction 2 1,102 t/year energy costs 158,000/year Investment 258,000 Return on investment 61% 1 For reasons of clarity, the figures are rounded off. 2 The calculation for natural gas (201.1 g CO 2 /kwh), oil (216 g CO 2 /kwh) and electricity ( g CO 2 /kwh) is based on the Global Emissions Model for integrated Systems (GEMIS).

3 Jury evaluation. Moll Marzipan GmbH has been awarded 2nd prize in the Energy Efficiency Award 2014 because it committed itself, as a medium-sized company, to the continued implementation of a package of energy efficiency measures, which led to a significant overall reduction in energy consumption. With the aid of an engineering firm and the active involvement of its trainees as compressed air police, Moll Marzipan GmbH has systematically implemented energy efficiency measures. Increasing energy efficiency, which is closely linked with energy control, has become a continual process for Moll Marzipan GmbH. Consequently, in 2014, Moll Marzipan GmbH decided that, in addition to undertaking an energy audit as per DIN EN , it would also introduce energy management and obtain DIN EN ISO certification. Moll Marzipan GmbH has demonstrated that the effort and expenditure associated with energy efficiency measures can pay off financially. On average, the energy efficiency measures pay for themselves in less than two years. Many of the measures implemented by Moll Marzipan GmbH can easily be applied at other companies. Moll Marzipan GmbH is therefore an excellent role model for other medium-sized companies. Technical project management shows trainees the air volume control Optimisation of the cold water supply: new energy-efficient refrigerator The international Energy Efficiency Award. Since 2007, dena has been rewarding excellence in increasing energy efficiency with the international Energy Efficiency Award. The prize-winning projects demonstrate the economic viability of energy efficiency measures in industry and production. Why not follow in their footsteps. Details of all previous winners of the Energy Efficiency Award and further information about efficient energy, in your company too, can be found at With the kind support of the premium partners: Prize winner profile. The Berlin-based food ingredients company Moll Marzipan GmbH specialises in the processing of almonds and nuts and their sale to major customers. In addition to raw pastes such as marzipan, persipan and nussipan, it also processes and sells preparations such as slivered, chopped, ground, roasted, crocant and candied products. The company currently has 85 employees. We were a member of the first Berlin Energy Efficiency Round Table and, as a result, have tackled, implemented and learned many measures. Through our actions, we would like to prompt other small and medium-sized companies to get to grips with energy efficiency and climate protection. Companies can learn a great deal from each other. Dr Armin Seitz, CEO of Moll Marzipan GmbH Compressed air police on the hunt for clues Contact. Moll Marzipan GmbH Torsten Gorzynski Project Management Ballinstrasse Berlin, Germany Tel: +49 (0) Fax: +49 (0) gorzynski@moll-marzipan.de Energy efficiency pays off. The Initiative EnergieEffizienz (Energy Efficiency Campaign) stands for efficient power use in all consumption sectors: Targeted campaigns are being used to inform end consumers in private households, in industry and commerce as well as in the services sector about efficient power use and to motivate them to take energy-efficient action. With the kind support of the media partner: Publisher: Deutsche Energie-Agentur GmbH (dena), German Energy Agency, Chausseestrasse 128 a, Berlin, Germany,Tel: +49 (0) , Fax: +49 (0) All rights reserved. Any use is subject to consent by dena. 11/2014, art. no An initiative by:

4 Jury evaluation. The jury has awarded Aluminium Norf GmbH 1st prize in the Energy Efficiency Award 2014 because the energy-intensive company has implemented several new approaches for an innovative annealing process beyond the state-of-the-art. Ultra-modern plant technology, such as computerised control of the precise thermal state of each individual aluminium coil, has led to a demonstrably significant reduction in energy consumption. Innovative technological solutions, such as comprehensive process measurement, selective process regulation and control as well as continual data collection and analysis, were used in concert. Aluminium Norf GmbH is an exemplary model for an energy-intensive industry, demonstrating how it is possible to enhance the optimisation potential in well-established, supposedly comprehensively optimised, large-scale industrial processes. The innovative technological solutions have resulted in the project becoming of significant interest to metal processing companies beyond the aluminium industry which operate multi-step, linked processes with integrated heat-treatment processes. The Aluminium Norf GmbH example should encourage companies in the metal processing industry to test and successfully implement innovative energy efficiency measures. Injector wall inside the furnace (photo: Susanne Dobler) Completion of the new furnaces The international Energy Efficiency Award. Since 2007, dena has been rewarding excellence in increasing energy efficiency with the international Energy Efficiency Award. The prize-winning projects demonstrate the economic viability of energy efficiency measures in industry and production. Why not follow in their footsteps? Details of all previous winners of the Energy Efficiency Award and further information about efficient energy, in your company too, can be found at With the kind support of the premium partners: Prize winner profile. Based in Neuss, Aluminium Norf GmbH (Alunorf) claims to operate the world s largest aluminium rolling and casting plant. It has 2,200 employees who manufacture semi-finished and intermediate products from aluminium and aluminium alloys. These are later further processed into food packaging, offset printing plates, vehicle parts as well as roof and wall cladding. The project to increase the energy efficiency of the annealing furnaces has enabled our production to be as efficient and climatefriendly as possible. As an energy-intensive company, every kilowatt hour that we can save enables us to remain competitive, making innovations like this energy efficiency project very important to us. Thomas Geupel, Commercial Director of Aluminium Norf GmbH Aluminium coils in front of a new furnace (photo: Susanne Dobler) Contact. Aluminium Norf GmbH Olaf Trepels Project Manager Koblenzer Str Neuss, Germany Tel: +49 (0) Fax: +49 (0) olaf.trepels@alunorf.de Energy efficiency pays off. The Initiative EnergieEffizienz (Energy Efficiency Campaign) stands for efficient power use in all consumption sectors: Targeted campaigns are being used to inform end consumers in private households, in industry and commerce as in the services sector about efficient power use and to motivate them to take energyefficient action. With the kind support of the media partner: Publisher: Deutsche Energie-Agentur GmbH (dena), German Energy Agency, Chausseestrasse 128 a, Berlin, Germany, Tel: +49 (0) , Fax: +49 (0) All rights reserved. Any use is subject to consent by dena. 11/2014, art. no An initiative by:

5 3rd prize: Energy Efficiency Award BSH Bosch und Siemens Hausgeräte GmbH Implementing a resource efficiency programme. As part of its Initiative EnergieEffizienz, the Deutsche-Energie-Agentur (dena) the German Energy Agency has awarded 3rd prize in the international Energy Efficiency Award to BSH Bosch und Siemens Hausgeräte GmbH. Run by dena with the support of its premium partners DZ BANK AG, Imtech Deutschland GmbH & Co. KG and Siemens AG, the competition is funded by the German Federal Ministry for Economic Affairs and Energy (BMWi) on the basis of a decision by the German Bundestag. Project description. In 2011, BSH Bosch und Siemens Hausgeräte GmbH instigated the Resource Efficiency 2015 programme with the objective of reducing total resource consumption within the company by 25 percent by 2015 compared with the base year of The large number of consumers and the different types of factories required a systematic approach comprising five individual steps: 1. Compiling and analysing the processes with relevant energy consumption, 2. Piloting process optimisation of energy-intensive processes, 3. Creation of guidelines to implement the measures, based on the findings, 4. Campaigns to implement the guidelines with targets for implementation at the individual sites, 5. Controlling system. Examples of energy efficiency measures implemented. Demand-related shutdown of systems Reduction of bath temperatures Replacement of lighting, e.g. switching from halogen floodlights to LED spotlights Modernising the compressed air supply and preventing leaks as well as lowering the pressure Installation of a frequency controller for pumps and air compressors Installation of energy-efficient conveyor systems for the assembly lines and inspection conveyors Process optimisations, e.g. lowering of temperatures, reduction of ventilation system performance in the assembly halls Figures for the energy efficiency measures implemented. 1 Energy costs million/year Energy consumption million kwh/year CO 2 reduction thousand tonnes/year Before optimisation After optimisation Savings Energy savings in percent 17% energy consumption million kwh/year CO 2 reduction 2 61,770 tonnes/year energy costs million/year Investment 6.5 million Return on investment 210% 1 For reasons of clarity, the figures are rounded off. 2 The calculation for natural gas (201.1 g CO 2 /kwh), oil (216 g CO 2 /kwh) and electricity ( g CO 2 /kwh) is based on the Global Emissions Model for integrated Systems (GEMIS). 3 Assumed electricity price: 0.15/kWh, assumed oil price: 0.05/kWh, assumed gas price: 0.04/kWh.

6 Jury evaluation. BSH Bosch und Siemens Hausgeräte GmbH has been awarded 3rd prize in the Energy Efficiency Award 2014 for its systematic implementation of more than 1,300 energy efficiency measures. This package of measures has resulted in a significant reduction in energy consumption in many processes and cross-sectional technologies across 40 factories and 53 other sites. The methodology and system chosen follows a consistent and integrated approach, with all the manufacturing processes being analysed with respect to their energy consumption and pilot projects being implemented for energy optimisation. In addition to utilising its in-house expertise, the company also consulted external partners such as universities and other professionals in the field of technical system planning. A number of internal campaigns were initiated with relation to six processes which are identical at all locations. The dedicated involvement of the employees is also making a significant contribution to the high energy savings. The energy efficiency measures implemented have paid off themselves in less than a year. Many of the energy efficiency measures can be applied to other industrial companies. BSH has succeeded in a most outstanding manner in combining resource and energy efficiency with economic success. Energy optimisation of the lighting systems Speed and temperature control as well as energy-efficient insulation The international Energy Efficiency Award. Since 2007, dena has been rewarding excellence in increasing energy efficiency with the international Energy Efficiency Award. The prize-winning projects demonstrate the economic viability of energy efficiency measures in industry and production. Why not follow in their footsteps? Details of all previous winners of the Energy Efficiency Award and further information about efficient energy, in your company too, can be found at With the kind support of the premium partners: Prize winner profile. BSH Bosch und Siemens Hausgeräte GmbH manufactures large household appliances, such as fridges, washing machines, tumble dryers, dishwashers, cookers and hobs, as well as small household appliances. BSH employs around 50,000 people across 42 production sites worldwide. With the increased energy efficiency during the lifecycle of the manufactured appliances, increasing efficiency during production has also become more important to BSH. As a result, BSH Bosch und Siemens Hausgeräte GmbH has implemented a group-wide resource efficiency programme. For us, sustainability is key to our corporate philosophy and part of our growth and value creation strategy. Consequently, the continuous energyefficient optimisation of our production processes is a top priority for us. Dr Peter Bauer, Head of Resource Management at BSH Bosch und Siemens Hausgeräte GmbH Speed control for electric drives in the press hall Contact. BSH Bosch und Siemens Hausgeräte GmbH Dr Peter Bauer Head of Resource Management Carl-Wery-Str München, Germany Tel: +49 (0) Fax: +49 (0) peter.bauer@bshg.com Energy efficiency pays off. The Initiative EnergieEffizienz (Energy Efficiency Campaign) stands for efficient power use in all consumption sectors: Targeted campaigns are being used to inform end consumers in private households, in industry and commerce as well as in the services sector about efficient power use and to motivate them to take energy-efficient action. With the kind support of the media partner: Publisher: Deutsche Energie-Agentur GmbH (dena), German Energy Agency, Chausseestrasse 128 a, Berlin, Germany, Tel: +49 (0) , Fax: +49 (0) All rights reserved. Any use is subject to consent by dena. 11/2014, art. no An initiative by: