Extrusion International 2-2020

48 Extrusion International 2/2020 COOLING TECHNOLOGY – CASE STUDY 1 and the refrigerant R410A which is still frequently used today has a GWP of 2,088. This way, even in the long run DRS won’t have to fear that their cooling system opera- tion could be affected by stricter environmental protec- tion regulations. A practical solution for every problem Today however, DRS had to overcome very practical challenges. The adjacent sites had to be converted, new production and storage areas had to be created within record time. Among other things, the company com- missioned six huge new silos, each with a capacity of 75 tonnes. Foundations were laid, the infrastructure rebuilt, and numerous new machines delivered and tested. Suit- able refrigeration technology was always on hand, but never in the way. “Reisner integrated our new cooling units directly into a container”, reports Andreas Seibel, “we only had to provide a foundation. On the inside the container was already perfectly piped and wired, so ev- erything went very quickly. We have gained more space with the new building, but we are still glad about every cubic meter that stays available for actual production purposes”. The container with the cooling technology is safely and securely located next to the silo system and can be quickly and easily moved to another location should need arise - for example following a production restruc- turing. With the connections from the container to the tank Reis- ner covered a special request asked by DRS and used ma- terials manufactured by the FRANK Group DRS belongs to. These materials are state-of-the-art PE100-RC pipes, that unlike standard PVC pipes are completely sealed by leakproof welding. Details like this as well as the reliable and confident work of Reisner’s project planning depart- ment made the difficult tasks much easier for Andreas Seibel. “We continued to produce during the reconstruc- tion phase, in three shifts and with an enormous mate- rial turnover. Each day, we had 30 to 40 trucks collect our finished pipes. Nothing could go wrong with the extra tasks. But we knew throughout the process that we could rely on Reisner”, he remembers, “our contact person was project manager Detlef Badziong. Thanks to his many years of experience he reacted confidently even to spon- taneous changes of plans. Thus, despite all efforts, the joint work on the project was really fun for everyone”. Cooperation for the future After the project phase which started in July 2019 and ended in November, DRS could start their day-to-day pro- duction as they had planned. Commissioning of their new cooling system in November went smoothly, as Reisner had already laid the foundation stone during the con- ception phase. Robust components and a maintenance- friendly design of the container make service operations an easy task. An integral part of this future-oriented plan is the cooling water quality. In pipe extrusion, water is of- ten highly loaded with solids which can ultimately impair the function of all plant components. Therefore, Reisner have installed their unique full flow return filter system inside their custom-made 20 m³ production tank. Without any risk of backwater flow nor great maintenance effort the filters keep the water clean and thus protect the en- tire production. Dosing systems for biocide and corrosion protection agents complement the water care concept and spare the DRS staff from having to handle the chemi- cals. For the near future, the project partners plan to jointly monitor how the energy-saving measures prove them- selves in practice. “As we have only been producing since November 2019, it is still too early to take stock,” reports Seibel, “but we will remain in close contact with Reisner in this regard. Together with Jurke Engineering we will monitor consumption and besides have the regular pre- ventive maintenance carried out by the Reisner team”. Reisner Cooling Solutions GmbH Schäferkampstr. 18, 59439 Holzwickede, Germany www.reisner-cooling.de DRS Deutsche Rohrwerke Sachsen GmbH 02625 Bauzen, Germany www.drs-rohrwerke.de The coolingwater is perfectly storedwithin large custom-madeReisner tanks. Thepipingwas accuratelymanufacturedbyReisner –on special request usingFRANKGroupmaterials What stays inside thesefilters cannot harmtheproductionanymore. The loadof solids is high inpipeextrusion coolingwater –noproblemfor the Reisner full streamreverseflowfiltration system