Nestlé operates a Maggi factory in Singen, Germany, which is over 125 years old and one of the group’s largest production sites in Germany. Every year, nearly 40 million bottles of seasoning and over 30 million cans of ravioli leave these historic halls. To make production CO₂-neutral in the long term, detailed insight into heat requirements is indispensable, especially with a view to future electrification via heat pumps.

The factory comprises 40 buildings with a wide range of media: from steam and hot/cold water to condensate. For a realistic assessment, 16 measurement points had to be mapped out, which presented several challenges due to varying states of matter and pipe configurations.

The approach

For the heat measurements, Katronic deployed the KATflow 150 (fixed installation) and the portable KATflow 230. At one location where temperature measurement was not required, the KATflow 200 provided the solution. Water flow measurements took place at twelve locations, primarily for hot water.

For five steam measurements, a trial measurement was first conducted to test feasibility. The conditions proved difficult: condensation on the inside of the pipes and irregular flow velocities made reliable on-site steam measurements unfeasible. At four of these locations, the focus was therefore shifted to condensate measurements, which did yield reliable results.

The result

The measurements revealed, among other things, excessive heat loss in a pipe for the hot water supply. By rerouting the pipe, this loss could be reduced. The tangible effect: an annual energy saving of approximately €10,000. The investment in measurement technology thus pays for itself quickly while simultaneously contributing to CO₂ reduction at the site.

Curious about what accurate flow measurements can mean for your installation? U-F-M is happy to help you further, from advice and on-site measurement to the rental or purchase of the right equipment.

This article is based on an article previously written and published by Katronic.