A South German parts manufacturer has optimized its ventilation systems using innovative technology. Experts at AIRnorm GmbH have demonstrated that a retrofit with the latest generation of ebm‑papst fans and a FanGrid can reduce energy consumption by 30 percent and significantly increase operational reliability.

The previous systems, which were operated with multi-speed motors and V-belts, displayed a number of weaknesses in terms of wear, maintenance and control, for example. AIRnorm analyzed the operating data, determined the current operating parameters and used the ebm‑papst FanScout program to select suitable fans and demonstrate savings potential. The outcome was that replacing the fans and the design of the new pressure wall would reduce the differential pressures, improve the flow and increase energy efficiency. AIRnorm calculated that the investment would be amortized in less than four years.

AIRnorm planned the project in close collaboration with Breuell & Hilgenfeldt, the ebm‑papst sales partner for retrofits. The retrofit specialists opted for the RadiPac C EC centrifugal fan from ebm‑papst as the new fan type. It features a compact 6 kW drive, which is highly efficient even in partial-load operation. Thanks to its plug & play capability and support bracket, the fan is already prepared for wall mounting. The automatic resonance detection in the RadiPac C helps prevent harmful vibration and premature bearing damage.

There are four production buildings with similar ventilation systems. As the exhaust air from the machinery in Hall 2 is extracted via the ventilation system, operational reliability plays a particularly important role. Any failure of the system would result in a production stoppage. That is why the retrofit began here, taking just three-and-a-half days during the summer shutdown. Removing the old motor, which weighed 320 kilograms, was achieved safely using hoisting equipment provided by the customer.

In addition to the energy savings, a crucial factor in favor of the implementation was the maximized operational reliability thanks to the redundancy ensured by installing a FanGrid. This allows several fans to be operated in parallel, which maintains output if one of the fans fails and prevents production stoppages. Two control cabinets with MDC control the fans, replacing the variable frequency drives that were previously in use. After commissioning of the system, all values were confirmed. In the future, the annual energy saving will amount to around 54,000 kWh.