Autoterminal Neuss is one of Germany's largest car transshipment centers and a full-service partner for a broad portfolio of process-oriented services ranging from appraisals to painting and conversions. On an area of more than 24 soccer pitches and with a total of 11,900 storage spaces, the company offers all the possibilities of a modern logistics company. As a partner of BLG Logistics and DB Cargo, ATN has a strong and international network. Around 100 employees ensure the professional preparation of
of vehicles and their transportation all over the world.
"In my view, CELESTRA is a truly unique selling point."
The requirements
ATN already had experience with decentralized infrared heaters. A KÜBLER system has been operating reliably in a branch since 2017. Due to the different areas of use in the elongated hall buildings, the decision for a decentralized heating system, with which individual heating zones could be specifically controlled, was made right from the start. Previously, the heating system was connected via a 400 m long 80-meter pipe - over this length alone, the heat losses were enormous, says Obladen. Further requirements were placed on convenient control and the energy efficiency of the new heating system. A 35 percent reduction in gas consumption was stipulated in the specifications - a basic requirement for the investment to be approved by the Group partners. The experienced maintenance manager was also keen for the heating system to be easy to maintain and for a reliable, well-known manufacturer. After examining various offers, the decision was once again made in favor of KÜBLER. Ultimately, in addition to the proven energy-saving technologies, the CELESTRA digital control system with its evaluation options and simple, self-explanatory operating concept was particularly convincing.
The technical solution
"Due to the relatively low ceiling heights in our hall buildings, we were limited in our choice of heating systems," says Obladen. Infrared systems from the PRIMA line were therefore installed in the five-metre-high finishing, paint shop and car wash wings, with a special corrosion-free stainless steel version in the car wash. PRIMA plus heating systems were used in the higher vehicle hall. The robust, slim standard line from KÜBLER impresses with its comparatively high infrared efficiency and excellent price-performance ratio. The new heating system is controlled by CELESTRA. The patented digital control system from KÜBLER is an important efficiency factor in ATN's heating concept, as it automatically adjusts the heating operation in the different heating zones to the ideal line. Shorter shifts, rest periods at weekends or on public holidays or other changes can be made very easily via the graphic control panel or on the PC. The self-explanatory "operating concept without operating instructions" is a unique selling point of the smart control system, as is the modular expansion concept. At ATN, the WinTec extension module is used for remote control, while TorOff ensures that energy losses are avoided in the vehicle hall when the hall doors are open. E.M.M.A. was also installed as an energy management system. The CELESTRA module provides ATN with real-time transparency across the entire heating process and provides the relevant analysis data for reporting, e.g. in accordance with DIN EN 50001. The entire hall heating project was delivered turnkey, including the electrical and gas infrastructure of the dark radiators. Thanks to the KÜBLER Powerline technology, which is also patented, data can now be transferred via the power grid - an important point for cost efficiency, as only one cabling line was required for both functions. The over 250 m long gas distribution line with several gas control stations was installed above ground in order to avoid the costs of underground construction and to be able to flexibly adapt the halls to future new processes. Due to the green roof at ATN, the exhaust gas pipes had to be routed through the façade. The dark radiators in the paint shop area were tested for compatibility with existing explosion protection requirements and installed. The cooperation between the teams at ATN and KÜBLER during the installation ran smoothly and in a spirit of partnership: the entire installation was completed on schedule during ongoing operations.
The result
Based on the experience of two heating periods - the decentralized heating system was commissioned in September 2022 - ATN's expectations for the modernization of heat generation have been more than fulfilled. "We had planned for 35 percent energy savings, we had hoped for 40 percent, but we have achieved over 70 percent," says Lutz Obladen. The refurbishment project reduced energy consumption by around 1,431 MWh per year, from 1,996 MWh in 2021 to 565 MWh in 2023. At the same time, almost 97 MWh of electricity was saved and CO2 emissions were reduced by 344 tons. Lutz Obladen: "The switch to decentralized infrared heating technology is a milestone in achieving our climate targets!"
Lutz Obladen has been with the company for 35 years and is responsible for the maintenance of technical systems at ATN. The experienced Head of Facility Management has accompanied and managed the energy-related refurbishment project at the Neuss site from the very beginning.
What was the initial situation at ATN?
To put it bluntly, our old heating system was a dinosaur. If only because we had no way of controlling the different heating systems with the central system.
The need to regulate heating requirements in the halls or work zones and the generation of process heat made it almost impossible to adapt to weather conditions. Ultimately, the high gas consumption was a double whammy: The cost burden and the environmental impact were simply too high. This was no longer compatible with our corporate goals.
You advertised infrared dark radiators right from the start, why?
I've been doing my job for a few years now and know the various technical possibilities. We also have a lot of experience with infrared systems from KÜBLER. In my opinion, dark radiators are the best solution because I can respond specifically to which area of the hall is used for longer or shorter periods of time, or where more or less physical work is carried out and therefore the temperature requirement is different. I was also in complete agreement with our consulting engineer from Enviconsult.
What particularly impressed you about the KÜBLER solution?
KÜBLER is a brand manufacturer. We wanted the reliability of still being able to receive support and, if necessary, spare parts in five or ten years' time. But I was really impressed by the control system. In my opinion, CELESTRA is a real unique selling point. Even in retrospect, it's a great thing with good evaluation options and is easy to use thanks to its great visuals - without having to read 70 pages of operating instructions. Settings can be made easily with just a few clicks to squeeze the last percent of savings out of the system.
What was the project like?
Of course, a project of this magnitude can sometimes be a bit of a pain. But the advice was great and the installation was superb. The team on site was really first class. Competent,
experienced and pragmatic. They found a solution for every problem. The arrangements also worked well. After all, we wanted to keep the business running. And that went smoothly.
How do your employees rate the new heating system?
In the first winter, the energy crisis and the requirement to reduce heating temperatures came with the system changeover. For some people, this took some getting used to at first. Like any change. Today, everyone is very satisfied and the working climate in winter is no longer an issue.
What conclusions do you draw after two heating periods?
There's nothing better than a topic you no longer have to think about. The system runs perfectly and the savings speak for themselves. What more could we want? The bottom line is that I would do everything exactly the same again.
The heating renovation project
ATN's elongated hall buildings at its main site in Neuss, with a total area of around 4,500 square meters, had been heated since 1994 by a gas-fired central hot water boiler system in conjunction with hot air blowers, whose energy consumption was literally through the roof. This, the associated high energy costs and the company's climate protection goals - ATN wants to achieve CO2 savings of at least 30 percent by 2030 compared to 1990 - were the deciding factors for Head of Facility Management Lutz Obladen to replace the "dinosaur" with a modern decentralized heating system. Together with Mr. Fiege from the consulting engineering firm Enviconsult GmbH & Co. KG, the current situation was analyzed in 2021 and a heat demand analysis was carried out in order to subsequently develop a concept for shutting down the 2 x 1.5 MW hot water boilers for process and heating heat. In addition to converting the hall heating to modern decentralized infrared technology, the refurbishment concept included direct firing of the paint booths and the installation of a much smaller boiler with 240 kW, as only the social wing and a smaller office building were to continue to be heated with hot water.
At a glance: The KÜBLER Group
KÜBLER GmbH is an internationally active group of companies and is regarded as a pioneer and innovation leader in modern infrared heating technology. The core business is the development and production of highly efficient premium technologies for energy-saving and climate-friendly hall heating. KÜBLER offers an exceptionally wide range of products for almost all types of halls and room environments.
Founded in 1989, the group of companies employs over 130 people and is one of the leading companies in the industry in Europe with locations in Ludwigshafen, Dresden, Hagen and Fegyvernek (Hungary) as well as numerous foreign agencies and a nationwide service network.
KÜBLER products and development services regularly receive awards. National and international awards include the Federal Prize for Outstanding Innovative Achievements from the Federal Ministry of Economics, the Bavarian State Prize, the German Sustainability Prize and the Innovation Prize from the state of Rhineland-Palatinate. KÜBLER is one of the 2021 Hidden Champions in the Palatinate and has been nominated for the BMWK's "IKU - The Climate and Environment Innovation Award" in 2022.
KÜBLER receives several prestigious awards for its innovative heating technology, the FUTURA multi-energy IR system: in 2022, the special prize "Innovative Technologies for Climate Protection" in the ISB's SUCCESS technology competition, in 2023 the "Innovation Award of the State of Rhineland-Palatinate" (for the fourth time), the "German Innovation Award" in the category "Winner Excellence in Business to Business Energy Solutions" and the FOCUS Special Mention at the FOCUS OPEN design award. In 2024, FUTURA receives the highest recognition at the PLUS X AWARD in the five categories of innovation, high quality, design, user-friendliness and functionality. KÜBLER receives the "High Customer Satisfaction 2024" award and is honored with the "Future Prize for SMEs" award for its FUTURA development management at the SME Future Day 2024.
