Retrofitted Heat Recovery systems save energy and increase film quality
In Komotini, Greece, Diaxon S.A. has been a constant in the production of BOPP film for over 26 years. With their two film stretching lines, they consistently deliver high-quality film for the production of food packaging applications. To maintain their competitive edge and improve efficiency, Diaxon aimed to make their lines more energy-efficient and cost-effective. Thus, the challenge was to find a solution that would not only save energy but also enhance the overall performance of their film stretching lines.
Heat Recovery Systems for a green footprint
As a suitable and economic solution, Brückner Servtec proposed the installation of Heat Recovery Systems (HRS). Those systems are highly effective in saving energy and reducing costs by focusing on the largest energy consumer in the system, the Transverse Direction Orientation (TDO) machine. By recirculating exhaust heat through a heat exchanger and preheating the fresh air, significant energy consumptions are achieved. Additional benefits include improved film quality, reduced condensation in the TDO, and lower greenhouse gas emissions.
In addition to the HRS retrofitting, including the installation of a fresh air duct in the oven to evenly distribute preheated air, also the control and monitoring systems were integrated into the existing IMC systems, too. Diaxon independently handled the piping to and from the TDO oven based on Brückner Servtec’s detailed drawings.
Extensive energy savings of up to 30%
The results were quickly evident. Nikos Papalazarou, Maintenance Manager at Diaxon S.A., shared his feedback: “Regarding the energy savings, [our] data indicates a decrease of an average ~30% on the load of the oil boiler burner, during production in both lines.” This feedback underscores the efficiency and sustainability of the HRS.
For the project managers Sebastian Salentin and Hubert Maier, the collaboration was particularly memorable due to the customer's extensive experience and proactive involvement. “Thanks to their know-how Diaxon independently carried out many tasks, such as the mentioned piping, which significantly shortened the installation times of the two Heat Recovery Systems, allowing us to stay on schedule. It’s always more enjoyable to work together when you know an experienced partner is involved!”.
The successful implementation of the heat recovery systems at Diaxon S.A. not only achieved the wished-for energy savings but also enhanced the overall efficiency and sustainability of their film stretching lines. This project highlights the importance of innovative solutions and a strong partnership towards a greener film production.
