Example of controlling air pressure in the production of tyres

Pirelli GmbH, Höchst in Odenwald

For over a century, the history of Pirelli has simultaneously been the history of the automobile. A history of high-performance segments, in which Pirelli is the market leader - both in original equipment and accessories, with 24 factories in 12 countries around the world.

A reduction in machine down-time of 5% and a saving of around €354,000 in energy costs in ten years: these are the results of comprehensive air-controlling, which has launched the Pirelli-production as the highest and the most systematically developed in the world.

More than 22,000 tyres a day establishes Pirelli as the leader - and compressed air is used for many steps of the automated production. For early detection of defects in the pneumatics, the maintenance in the field of construction machinery, MT, installed around 300 measurement fixtures by the manufacturer Postberg + Co Air Control GmbH, where you can easily mount the air pressure meters and establish, by comparison, the values of leakage. With this method, which we have applied since 1996, Pirelli has reduced the down-time of machines by 5%. In addition, the cutting down, over the past decade, of between 10 to 20% of air consumption, achieved a saving of approximately 5.9 million cubic meters of expensive compressed air power. At an air pressure price of €0.06 / m, this results in a saving of €354,000 and a successful contribution to CO2 reduction. In just the first two months of 2007 savings of €170,000 towards costs of €1,500 have been achieved.

Example metering of surface-mount assembly machines for the production of air conditioners in the automotive industry

Behr-Hella Thermal Controls GmbH (BHTC), Lippstadt

The Behr-Hella Thermo Control GmbH (BHTC) was established in 1999 as a joint venture between Behr GmbH & Co. KG and Hella KGaA Hueck & Co. Today,with approximately 1,000 employees worldwide, we are one of the world's leading manufacturers of control panels, and control units for vehicle air conditioning.

At a flow rate measurement on the SMD placement machines within the company BHTC an average air consumption of 1,430 l / was found. Main consumers are Venturi Düsen for generating a vacuum to the platinum hooks.

Within the framework of an IST analysis, the actual compressed air costs were calculated in € per cubic meter. On this basis, the alternative SMD placement machines with a vacuum pump were tested economically. Identical machines with vacuum pumps are supplied by the manufacturer. These costs, by the already factory-integrated vacuum pump, are higher with the new investment. The manufacturer, however, does provide an upgrade package, making the substitution of the compressed air possible. Thus, the cost comparison was possible.