Intelligent air technology makes jobs at Stiwa attractive and future-proof
The STIWA Group is consistently on course for growth, and the Gampern site has just been expanded for the new machining division. Stiwa produces metal parts for the Automation division (plant engineering) and for the automotive industry at the site. The investment will bundle and expand the machining expertise. For the region, this means new and high-quality industrial jobs.
Initial situation
The restructuring and expansion of the machining division was due to high demand. Last year, a 10,000 square meter production hall was built and the existing machinery was relocated to the new production hall, along with nine additional machining machines. As part of the new building, the company optimized its entire production logistics - including the flow of materials and goods. The production hall and each individual workstation were designed to be bright and spacious.
Combination of exhaust air technology, room air technology and energy technology
In the new hall, Kappa has linked the exhaust air technology with the ventilation technology and energy technology. The overall solution ensures that the individual modules are perfectly coordinated. This begins with the separation of cooling lubricant emissions and ends with heating and cooling. The implemented system ensures draught-free ventilation of the halls, optimum temperatures and lower energy consumption. This has increased functionality and reduced investment and ongoing energy costs.
Exhaust air technology for capturing direct cooling lubricant emissions
They reach the AirdryTM high-performance separators from Kappa via a dense pipe network. On all five machining lines a Kappa AirdryTM was installed. The cleaned exhaust air from the filter system is fed into the ventilation system.
This is ventilation technology by Kappa: perfectly tempered fresh air and removal of diffuse cooling lubricant emissions and heat
Fugitive emissions cannot be prevented during machining on the individual machines. They also occur during manual work, for example during cleaning.
To avoid stressing the workers, fresh air is introduced draught-free on the hall floor. Kappa DiffusorsTM were installed throughout the hall for this purpose, they ensure that the fresh air diffuses in. This air does not mix with the hall air and flows around all obstacles, the workers in the entire hall are supplied with fresh air over a wide area. After just a short time, a stable lake of fresh air forms in the entire work area, it displaces both the emissions released and the waste heat from the working and recreation areas upwards to the hall ceiling. Emissions and waste heat are captured and dissipated completely and over a wide area with adjustable Kappa COCTM extraction panels.
The emissions are filtered by two Kappa MTATM exhaust air purification and air treatment centers. They are attached to the hall roof and filter a total of 90,000m³ of exhaust air every hour. The MTA systems are equipped with a multi-stage exhaust air purification unit, the first filter stage has an automatic cleaning unit, which ensures highly effective separation and a high air flow rate with low system resistance.
Energy technology ensures efficient and economical temperature control
The waste heat is recovered after the exhaust air purification unit in the integrated low-temperature heat exchanger. The heat exchanger is also equipped with an automatic washing device. This ensures a consistently high level of efficiency. In the Kappa MTATM systems, the supply air is treated. It is heated with the energy recovered from the extract air flow. In the downstream heating and cooling module, the supply air is heated or cooled as required. The entire hall is thus efficiently and economically heated to the desired temperature and the required temperature range can be maintained all year round.
What does the customer say?
"When planning the new production hall, it was clear that cost-effectiveness and sustainability must not be contradictory. Attractive workplaces are efficient workplaces. Air technology and energy technology are extremely important in a production facility with machining operations. In Kappa, we have found a partner who does not compromise, who thinks holistically and together with us. The result is impressive in every respect. The workstations are modern, pleasant and safe, and the investment is sustainable and economically viable." Dirk Algermissen, Head of Construction Planning at the STIWA Group.
