An Investment That Pays Off: The Most Energy-Efficient Temperature Control Units by HB-Therm, Distributed by LUGER spol. s.r.o.

Temperature Control Units That Pay Off

The iceberg model, often used in business administration, illustrates very well that the total cost must include not only the purchase cost of a machine or piece of equipment, but also ongoing and hidden costs. For example, operating costs over the life cycle of production equipment are generally estimated to be ten to fifteen times higher than the purchase cost.

Consider Capex and Opex Together

When discussing Total Cost of Ownership (TCO), many people overlook the fact that it is not "just" about purchase costs (capex, capital expenditure). Ongoing operating costs are equally important (Opex, operating expenditure). They represent, so to speak, the substantial part of the iceberg below the water, allowing the total expenditure on an investment, in this case a temperature control unit, to be comprehensively mapped over its entire service life.

HB-Therm equipment has proven to be a long-term investment – with a service life of at least ten years, depending on how the equipment is handled. Usage statistics from many customers also demonstrate this. Many companies still use Series 3 or 4 temperature control units with more than 100 000 operating hours, equivalent to continuous operation for more than eleven years. The current Series 6 units (Fig. 1) offer operators valuable support, just like their predecessors – although on a much more extensive scale. Through operation-dependent displays for upcoming maintenance or preventive warnings, they effectively help identify and prevent risks of damage in good time.

The "family gallery" (from left), with Series 3 from 1990 and Series 4 and 5 through to the current Series 6.

Looking at the entire life cycle of temperature control units reveals different economic and environmental impacts than considering only the purchase price itself. The weighting of individual items in the TCO assessment shifts significantly in some cases, because variables such as sustainability or the impact of new purchases on the CO2 footprint of products and production are then also taken into account. A unique advantage of Thermo-6 units in this context is the lifetime warranty on the heating element and flow measurement. This not only saves on spare parts, but also prevents unplanned interruptions to operations due to repairs and, consequently, production downtime lasting several hours.

The Impact of Comprehensive Standard Equipment on TCO

When examining the purchase of temperature control units in more detail, sustainability and the CO2 footprint, energy efficiency, control and technical characteristics also come into play alongside standard equipment and functions. While many suppliers attract customers with low prices for their basic products, which have only minimal equipment, customers notice the very favourable ratio of standard equipment to optional equipment in Thermo-6 temperature control units: In the technical specifications, the standard equipment is described over an entire page, while the optional equipment consists of just five additional functions. These are leak-stop mode, connections for an alarm and external control, a connection for an external sensor, return filter monitoring and mould emptying with compressed air.

From the manufacturer's perspective, the extensive standard equipment of Thermo-6 units makes sense: The equipment functions are implemented through software or hardware technology and are essential for the safe, reliable and sustainable operation of temperature control units. In addition, their versatility, supported by the company's strategy, enables solutions for many different tasks.

Lower Operating Costs with a Variable-Speed Pump

The software and hardware functions included as standard have a beneficial effect in the medium and long term. With the "Energy-Control" control assistant, the optimum operating point can be achieved in just a few steps. The result is up to 90 % lower energy consumption. The assistant relates variable rotational speed, speed, flow rate, temperature difference and energy savings to their effect. Identifying the optimum operating point is made easier by a simple visual display showing the current pump speed, the temperature difference between supply and return in kelvins, and the annual savings in euros.

HB-Therm uses variable-speed pumps as standard in all Thermo-6 units, which deliver immediate cost reductions thanks to their energy-efficient operation. This allows the pump characteristic curve to be adapted to the application so that the required flow rate is achieved with minimal energy consumption. In most cases, however, it is not clear from the outset what the correct temperature control is for a given process. The control system of HB-Therm units therefore offers the option of selecting a suitable preset Eco mode (Fig. 2)

The unit controls allow you to select various preset Eco modes to optimise the unit's energy consumption in every case.

– with automatic control
– with constant pump speed
– with constant flow rate
– with constant temperature difference,
so that the unit's energy consumption can be optimised in every case.

Energy-Efficient Direct-Drive Pumps

The direct-drive pumps in Series 6 for applications up to 100 °C further reduce energy consumption. Their special design prevents eddy current losses, and energy consumption is reduced by a further 20 % compared with the already efficient "normal" pumps with variable speed.

"Direct Drive" pumps are available in two versions: type 4T for standard applications with flow rates of up to 65 l/min and 6P for higher-performance applications with a capacity of up to 140 l/min. The pumps impress with their compact design, which delivers three times the performance of conventional pumps of this size.

Due to the complexity, it would be possible to dispense with developing new, more efficient pump technology that would also be more attractive when purchasing, i.e. in terms of procurement and logistics. However, the aim of using these pump types is to achieve the best possible performance for every application and every type of unit through development. Such optimisations have a far-reaching effect thanks to economies of scale in large production halls or at a global level – which is a central part of HB-Therm's fundamental idea of achieving sustainable improvements even with the smallest contribution per unit.

Energy Efficiency Through the Right Unit Design

Energy efficiency was the top priority in the development of Thermo-6 units. As part of the systematic further development of the proven Thermo 5 units, the unit concept was comprehensively improved; including the entire hydraulic concept, which has demonstrated impressive energy consumption performance since Series 4 thanks to its tankless hydraulics with a correspondingly lower circulating volume of 1.4 l (Fig. 3). Both the connecting components and specially developed modules, such as the heater or the proportional module for bypass control, were further optimised to ensure the smoothest possible flow behaviour of the medium. The result is lower pressure losses, which means lower pump energy consumption at the same output.

Energy-efficient temperature control unit with tankless hydraulics and a minimal circulating volume (1.4 l), modular design and hydraulics with optimised flow resistance.

Reduced stress also reduces wear, which in turn has a positive effect on service life – two aspects contributing to positive TCO and ROI. Expressed in figures, this means that using a Thermo-6 temperature control unit consumes approximately 27 % less energy compared with Thermo-5 – simply by designing the unit accordingly. If you also take into account the 20% saving from "Direct Drive" technology, this means an energy saving of 42 % for the same application. And this is despite the similar design of Thermo-5 with tankless hydraulics and modular construction.

Immediate Cost Savings of 559 EUR per Year

HB-Therm's "Energy Consumption Comparison" (ECC) program can be used to compare generations. It compares two HB-Therm units based on real-world operating values and shows the savings potential of new technologies depending on the application. The sample calculation compares identical variable-speed units from Series 5 and 6. Despite the same operating mode, it is possible to save 559,- EUR per year by switching from the older to the newer series (Table 1).

Comparison of the energy consumption of HB-Therm Series 5 (current) and Series 6 (new) temperature control units.

If you look at this over a service life of 15 years, for example, it amounts to 8.385,- EUR – meaning that Thermo 6 units not only pay for themselves, but also generate a profit thanks to their highly efficient operation and have a positive effect on ROI.

The Vision of the Most Energy-Efficient Temperature Control Unit

The energy efficiency of equipment also affects sustainability and the CO2 footprint. In the case of HB-Therm – in addition to energy-efficient operation at the customer's premises – a second factor also plays a role here: energy-optimised and sustainable production of the units at the plant in St. Gallen. For HB-Therm, a commitment to sustainability is a central aspect of the company's identity, which is reflected in the continuous optimisation of its own CO2 footprint. A high degree of lean in-house production, an ever-increasing level of automation, consistent monitoring of supply chains and engineering under one roof are the keys to HB-Therm's pioneering role in developing what it considers to be the most energy-efficient temperature control unit on the market, Thermo-6.

Taking "Embodied Energy" into Account in the Total Cost Analysis

How is so-called "grey energy" included in the total cost of ownership (TCO) analysis? The focus is on the entire product life cycle, both from HB-Therm's perspective and from the customer's perspective: from development through production and application to recycling. HB-Therm considers this as early as the development stage: What about recycling costs at the end of the product's service life? Or will you give the units a "second chance" and thus avoid complete disposal? While many companies today plan an amortisation strategy with a fixed end of service life, HB-Therm strives not only to keep operating costs low throughout the service life of the units, but also, where supply chains and manufacturing technologies permit, to extend their service life through the long-term supply of spare parts.

Even when developing and designing their units, the Swiss temperature control specialists keep the life cycle and end of service life in mind. Thanks to the modular design of the units, individual modules can be replaced at any time, without having to dispose of the entire unit. Modern technologies can thus be retrofitted even to the first versions of the respective series, so that the unit not only has a longer service life, but also incorporates the latest technology. If the units have actually reached the end of their service life, HB-Therm or the relevant representative – provided that transport is worthwhile – will take them back and recycle them professionally and sustainably.

Quality Pays Off for Sustainability

The quality of Thermo-6 temperature control units is also an important factor in sustainability. The components of the units are made from durable, high-quality materials, such as stainless steel, brass or high-quality fibre-reinforced plastics, which have been specifically selected for demanding applications. This means that the overall efficiency and sustainability of the units are positively influenced by their long service life.

Simple, intuitive operation of the units also pays off in terms of quality. Using various sensors, such as temperature sensors, pressure sensors and the corresponding software for evaluation and identification installed in the units, the monitoring of important functions related to productivity and production safety is highly automated – minimising sources of error and thus reject rates. The "automatic setting" functions enable the units to continuously optimise the operating process. In addition to extensive sensor monitoring, Series 6 units also provide safety through hose rupture detection.

Digitalisation Makes Temperature Control Smart

When it comes to the digitalisation of temperature control, Series 6 is one of the pioneers in the industry. Many people talk about a digital twin, but HB-Therm already has one (Fig. 4).

From now on, the free e-cockpit app provides access to the digital twin of the temperature control units regardless of time and location.

Recording process data, unit history, "on-site" troubleshooting, maintenance orders and spare parts deliveries through unit-specific documents such as certificates, calibration data, spare parts lists, operating and installation instructions: Series 6 units offer all customers who wish to use it unrestricted, data-secure access to the digital world (Fig. 5).

Using the Gate-6 gateway enables extensive digital services, such as the transfer of analytical data or remote connectivity.

Also with all relevant process data on any mobile device. Digital capabilities were expanded again for the Fakuma 2024 trade fair. This means that many new digital functions can be used free of charge via the e-cockpit app even without the Gate-6 communication gateway (Fig. 6).

The free e-cockpit app enables all Thermo-6 users to easily enter the digital world of temperature control technology – for greater efficiency and control.

The Gate-6 communication gateway is authorised for remote function applications.

Conclusion: It Is All About the Overall Picture!

Anyone buying temperature control units who bases their calculation solely on the purchase price is being very short-sighted. If, on the other hand, quality, energy efficiency, durability and sustainability are taken into account when purchasing, considering the total costs will lead to a well-founded investment decision. The same applies to ROI, an important metric when it comes to investing. Because if all the important purchasing criteria that say something about the future viability of the investment are included in the calculation, the payback period for units with a long service life will also be much more favourable.

A Trial Without Obligation

In more than 60 countries, interested parties can request a free loan of a unit through the company's sales partners and experience the benefits of this technology in real-world use.