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Case Study - Bridgnorth Aluminium Ltd
As the UK's only manufacturer of lithographic printing plate material – and one of only three producers in Europe – for Bridgnorth Aluminium Ltd, producing high quality products efficiently and effectively is paramount. Based in Shropshire, Bridgnorth Aluminium Ltd has a purpose built, state of the art rolling mill and stretch levelling line, allowing the company to specialise in hot and cold aluminium rolling, annealing and levelling. Following a period of sustained growth for the business, an expansion of its facility led to the installation of two additional hot water boilers as part of its new litho finishing line, with a payback period of just two years.
For the company’s lithographic material, it is critical that the material’s surface remains unmarked and unblemished when a finishing chemical is applied. To achieve this, a hot degreassant, which is heated using industrial hot water boilers, is applied to the surface, giving the plates a flat surface for printing.
As with any new manufacturing process, efficiency in terms of both time and cost was a key consideration. However, coordination, trust and flexibility played a vital role in the successful installation and, following a competitive tender process, Bridgnorth Aluminium Ltd opted to work with Bosch Commercial and Industrial.
Following the tender process, it was agreed that Bosch Commercial and Industrial would be able to provide not only the products necessary for the expansion but also the support structure needed to cope with the logistical and organisational demands of the project.
In order to increase capacity for the site, while maintaining high efficiency standards, two UNIMAT UT-M 1,400kW hot water boilers were installed to heat a primary circuit which raises the temperature of both the chemical treatment and hot water rinse.
Bosch’s innovative flue gas heat exchanger allows heat from the flue to be returned to the system, saving energy and increasing efficiency by 2% – an efficiency measure which equates to a saving of up to £18,000 a year. As a result of the flue gas economiser, the company is able to achieve a payback period of just two years.
Planning for success
One of the challenging aspects of this installation was the fact that the boilers had to be married up with the rest of the manufacturing line’s creation. For example, to reduce energy-losses, short pipelines were designed as part of the system, which made access to the site difficult. Additionally, the commissioning timings of the different components within the line had to align, in order to minimise the line’s downtime and test periods.
To combat these logistical challenges, Bosch took a flexible approach and worked closely with other site suppliers in order to achieve a joined-up installation within both time, space and budget constraints.
In a project that totalled 12 months to complete, the installation and commissioning of the boilers themselves took just 2-3 months.
Simon Edwards, Mechanical Maintenance Manager at Bridgnorth Aluminium Ltd, commented: “This was a complex project and we needed a hot water boiler supplier that we could discuss all our needs with, which would be on hand post-installation as well as pre.
“For us, Bosch was the ideal fit; offering excellent support and a total solution with a flexible product. The team were extremely accommodating and their knowledge on how to approach a problematic situation really shone through. The agreed service contract has proved invaluable to us as the line has become more established and we can be rest assured that any maintenance needs are covered.”
Rob Brown, Special Projects Sales Manager, at Bosch Commercial and Industrial, commented: “We are delighted we have been able to help a leading UK manufacturer continue to expand and develop. The UNIMAT UT-M hot water boiler was perfectly suited to the site due to its flexibility and energy efficient characteristics.”
Case Study - Bosch Rexroth
“The benefits of the new system are already evident with planned energy reductions already being realised. The CHP solution as implemented not only meets in excess of one third of our electrical needs, it also provides 100 per cent of our office and shop floor heating and process needs. As a consequence, we have the double benefit of both substantially reducing our energy bills and significantly driving down our CO2 emissions by over 30%, meaning that our corporate environmental targets for 2020 are already realised.”
Derek Donnelly, health, safety and environmental manager at the Glenrothes facility
When Bosch Rexroth introduced its worldwide environmental policy targeting a substantial reduction in CO2 emissions across all its sites, the company’s Glenrothes facility took the opportunity to implement an innovative heating and power solution.
The site manufactures hydraulic motors for fork lift trucks, mini excavators and other mobile plant for household names such as JCB and Caterpillar. It a significant consumer of both gas and electricity with a large number of machines and test rigs in both the main manufacturing area and the R&D facility. Additionally, the shop floor was heated by a number of large gas-fired radiant heaters, which were over 20 years old, whilst the office space was heated by multiple gas boilers, some of which were in excess of 25 years old.
After extensive analysis, it was concluded that there was potential to produce one third of its total electricity requirement with the installation of three 140kW (electrical) CHP units. The units work 24 hours a day, seven days per week, with four 100kW GB162 boilers as heating back up during planned maintenance cycles.
In addition, hot water is stored in three 10,000 litre buffer tanks which can hold hot water at 90oC. The entire system is controlled by a full building management system, which controls and measures all inputs and outputs from the CHP units and can be adjusted on PC’s located around the site.
Crucially, the installation of the new CHP system was achieved with no disruption to the site’s manufacturing capability. In fact, the entire plant room, including CHP units, pipework, back-up boilers and controls at the Glenrothes site was manufactured off-site and then shipped to Scotland as a completed plant room, ready for connection and commissioning. The plant room is effectively a plug and play solution with everything manufactured and put together off-site with no welding or construction on site