BAFA energy consulting / technical planning for heat recovery at the Czerr confectionery
PROJECT DESCRIPTION
The Konditorei Czerr GmbH & Co. KG (Konditorei Czerr) is a Berlin-based, family-run bakery and confectionery business with one production site and a total of 8 branches. In preparation for fundamental energy modernization measures, GICON® - Grossmann Ingenieur Consult GmbH (GICON® - Consult) was first commissioned with the implementation of an energy audit according to DIN EN 16247-1 within the framework of an energy consulting in medium-sized businesses funded by the Federal Office of Economics and Export Control (BAFA).
In the course of the preparation, an energy source and energy consumer analysis was initially carried out. This involved evaluating the energy consumption of the heating oil and electricity previously used at the site over the last three fiscal years and recording, analyzing, and assigning the energy consumption of the energy consumer to consumer groups. The analysis was supported by temporary measurements, among other things. Based on this as-is analysis, various measures for increasing the energy efficiency of the production site were identified in the further course of the project and evaluated with regard to feasibility and the energy and economic savings potential.
The main focus was on the baking oven, the fermentation process and the refrigeration technology as well as the use of waste heat from these consumers (to cover the heating, hot water and process heat requirements).
The results were summarized in a final report corresponding to the specifications of the BAFA funding program "Energy consulting in medium-sized businesses". In addition to consulting for the increase of energy efficiency, the application documents for the investment subsidies for the implementation of the complex measure were prepared by GICON® - Consult and the confectionery Czerr was supported during the application procedure. The subsidies applied for in the "Berlin Program for Sustainable Development (BENE) were thereby approved in full amount of more than € 190,000.
In a second, continuing project, GICON® - Consult was commissioned with the heating engineering design for the integration of the existing waste heat sources. Here, the waste heat flows of the exhaust gas of the deck oven and the condensers of the refrigeration plant and the deep-freeze cell were integrated into the heating system to be adapted and optimized. For better utilization of the recovered waste heat, a heat storage system was also designed.
As a result, highly-efficient natural gas-fired baking oven technology (instead of oil and electric ovens) and highly-efficient refrigeration technology are now used, the waste heat from which is harnessed via the heat recovery system and covers the major share of the heat required for space heating (via radiators), water heating and process heat generation (for the fully automatic fermenter). To cover peak loads and for reasons of redundancy, a gas condensing boiler was also installed, which can cover the heat demand at times when there is no usable waste heat. The new system also replaces the previous hot water generation by means of a decentralized electronic instantaneous water heater and the heating generation by means of an oil-fired boiler.
PROJECT DEVELOPER
PERIOD OF PERFORMANCE
2016 – 2020
KEY PERFORMANCE AREAS
- Energy carrier and consumer analysis
- Temporary measurements at various energy consumers
- Development of energy efficiency measures
- Evaluation of saving potentials incl. calculation of economic efficiency
- Support with the call for subsidies
- Heating design
Heating and hot water system (HOAI
service levels 1-3, 5 and 6)