Local heating with a future: climate-neutral
heating for the next generation
LK Metal references
LK Metal references
– Customer: Abel Wellpappe GmbH & Co KG
– Sector: Manufacturer of packaging material
– Project year: 2022
– Location: Westheim (Mittelfranken)
– LK Metall products used:
Auxiliary heating systems for hot water (district heating), consisting of axial fans and pump hot water registers
Abel corrugated board
The long-established company Abel Wellpappe produces environmentally friendly packaging solutions – and wanted to extend this claim to its heat supply. The existing heating technology was still oil-based, which was neither ecologically nor economically up-to-date. The aim was therefore to convert to a sustainable water-based local heating supply without having to replace the entire system technology.
In 2022, the decision was made to switch to local heating. Since then, the company has been sourcing its heat from a regional provider organized as a cooperative that uses biogas and wood chips as energy sources. Thanks to this measure, Abel Wellpappe can now operate its production in a climate-neutral manner – a consistent step in terms of active and practical climate protection that shows how companies can take responsibility.
LK Metall developed an intelligent modernization solution in which five existing hot air heaters were retrofitted with individually designed auxiliary heating systems. These consist of efficient axial fans and powerful hot water registers that are connected to the district heating network.
The new technology was installed under the hall roof to save space and was precisely matched to the existing systems – both hydraulically and in terms of air technology. The heating output is divided between two systems with 100 kW each and three systems with 150 kW each.
In addition, when converting to local heating in halls 3 to 8, existing LK hot air heaters were made fit for the new heating system by replacing the oil burners with PWW registers. In Halls 1 and 2, LK Metall installed a modern GCS (Green Climate System) hot air generator, which was specially developed for production and logistics halls. A two-room control system enables the two hall areas to be heated separately. Thanks to an integrated mixed air system and intelligent interval control, ventilation and night cooling can also be controlled individually – for a pleasant and energy-efficient indoor climate at any time of year.
The result: a sustainable heat supply in just three weeks
Thanks to the smooth conversion, Abel Wellpappe was not only able to improve the company’s carbon footprint, but also reduce heating costs in the long term – without interrupting production. The conversion was subsidized and implemented within just three weeks.
The use of the LK GCS warm air generator, which can be operated not only with local heating but also with other regenerative energy sources, is particularly forward-looking. For example, a special heating and cooling coil has been integrated, which is connected to several heat pumps via a cascade – filled with the environmentally friendly refrigerant R32 or the natural refrigerant R290. An integrated filter permanently cleans the intake air of dust and dirt particles.
The investment is also subsidized by the Federal Office of Economics and Export Control (BAFA): Up to 40% of the costs can be reimbursed – a strong financial incentive to switch to a climate-friendly heating solution.
Hall heating
– High energy efficiency thanks to central heat generation
– Short transport routes
– Can be flexibly combined with biomass or solar thermal energy
– Space-saving installation
– Reduced maintenance requirements
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