Flender, a manufacturer of industrial gear systems, has implemented a new waste heat recovery system at its Bocholt facility, significantly reducing energy consumption and carbon emissions.
The innovative process utilises waste heat from the company’s in-house hardening facility to heat buildings across the site.
The new system, centred around a high-capacity heat pump, is expected to save 2.4 million kilowatt hours of natural gas and reduce CO2 emissions by 400 tonnes annually.
This achievement marks a significant step in Flender’s ongoing efforts to enhance sustainability in its production processes.
At the heart of the new heating system is a 622-kilowatt heat pump, approximately 75 times more powerful than a typical residential unit.
The process begins in the hardening shop, where cooling water at 32 degrees Celsius is used to heat the site’s heating circuit water through a heat exchanger.
The heat pump then raises the water temperature to 60 degrees Celsius, which is suitable for building heating.
Robert Iding, Project Manager at Flender, highlighted the uniqueness of the setup, stating: “This is a unique process in this setup and scale.”
The six-month construction project involved installing the heat pump, laying new water pipes across the company site, and updating the heating distribution system.
This comprehensive approach has allowed Flender to heat most of its halls and buildings in Bocholt using energy recovered from the hardening process, significantly reducing reliance on conventional gas heating.
Andreas Evertz, CEO of Flender, underscored the company’s commitment to sustainability: “As an industrial company, we have a large responsibility to society and our climate to make our production as sustainable as possible.”
Kimberley ten Broeke, Head of Corporate Social Responsibility at Flender, highlighted the project’s economic viability: “The new heating system is a long-term investment that pays off.
“We are reducing our energy consumption and setting another positive example in the industry.”
This initiative aligns with Flender’s broader sustainability goals, which have already led to a 79 per cent reduction in Scope 1 and 2 CO2 emissions since 2015.
The company’s efforts in sustainable manufacturing and energy efficiency have been recognised with the German Sustainability Award 2024 in the mechanical engineering category.
As industries worldwide seek to reduce their environmental impact, Flender’s innovative approach to waste heat recovery sets a new standard for sustainable manufacturing practices in the gear production sector.
