027-11 Lohr, 2011-03-25

Rexroth Energy Efficiency Advice Gets Factories into Shape

The era of smoking factory chimneys is a thing of the past for the industrialized world. However, industry is still responsible for generating approximately a third of all carbon dioxide emissions in Europe as a result of its energy consumption alone. In emerging markets such as China, the proportion is significantly higher. As the pressure to become more energy-efficient increases, numerous companies are taking the initiative by making voluntary commitments. Energy efficiency in factories can be improved quickly and noticeably using a systematic approach like the one developed by Bosch Rexroth. This approach also meets the demand for such investments to be profitable, as first experiences have shown that the investment quickly pays for itself thanks to reduced energy consumption — in one case, in the first year alone.

As a manufacturer of all types of drive technologies, Bosch Rexroth offers more than just energy-efficient components for newly developed machines. Through systematic energy-efficiency advice and its practical implementation, Rexroth supports companies in all industries in significantly increasing energy efficiency in manufacturing lines that have already been installed and in fully equipped factories. In doing so, an unusually holistic approach gives Rexroth an overview of the whole life cycle of a machine and every factor affecting its energy consumption — from construction and daily operation to the maintenance process. With Rexroth 4EE (for Energy Efficiency), Rexroth takes a consistently holistic approach in which four concepts play the key role: "Efficient Components", "Energy Recovery", "Energy on Demand" and "Energy System Design".

As part of the process of optimizing an installed system, Rexroth energy efficiency advisors analyze the current situation and identify potential savings across the entire value addition chain and for all machine types. Based on this analysis, the specialists devise measures to reduce consumption and back them up with profitability analyses. Unlike companies providing consultancy services only, Rexroth provides a comprehensive service that also covers the implementation of the measures set out — monitoring of their success included.

Using this approach, Rexroth modernized a highly complex DuoCell manufacturing cell from the 80s in Volkswagen AG's Salzgitter plant. Rexroth's modern, open automation structure offers considerable benefits such as flexibility and greater availability, while also reducing energy consumption. In addition to the efficiency-optimized motors, regulated intermediate circuits now reduce energy consumption for the energy-recovery regulators. Analysis software integrated in the Rexroth control measures energy consumption online as well as the duration of every movement. These measurements and analyses provide important assistance in minimizing energy consumption via optimum movement guidance, without having a negative impact on productivity.

Using its 4EE approach, Bosch Rexroth will also lower CO2 emissions from its own plants by 20% in all plants worldwide by 2020. The experience that Bosch Rexroth has gained in doing so is also being fed into its future-oriented energy efficiency consultancy service for machine manufacturers and end users.

Bosch Rexroth AG is one of the world’s leading specialists in the field of drive and control technologies. Under the brand name of Rexroth the company supplies more than 500,000 customers with tailored solutions for driving, controlling and moving. Bosch Rexroth is a partner for industrial applications and factory automation, mobile applications and using renewable energies. As The Drive & Control Company, Bosch Rexroth develops, produces and sells components and systems in more than 80 countries. In 2009 Bosch Rexroth part of the Bosch Group, achieved sales of around 4.1 billion Euro with 34,200 employees.

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The Bosch Group is a leading global supplier of technology and services. According to preliminary figures, some 283,500 associates generated sales of 47.3 billion euros in the areas of automotive and industrial technology, consumer goods, and building technology in fiscal 2010. The Bosch Group comprises Robert Bosch GmbH and its more than 300 subsidiaries and regional companies in over 60 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. Bosch spent some four billion euros for research and development in 2010, and applied for over 3,800 patents worldwide. With all its products and services, Bosch enhances the quality of life by providing solutions which are both innovative and beneficial.

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Susanne Herzlieb
Maria-Theresien-Straße 23
97816 Lohr am Main
Phone: +49 9352 18-1573