Pfungstädter Brauerei had good reasons to replace their existing
system although everything seemed to work.
About the company
Pfungstädter Brauerei is a family-owned brewery in Germany.
It has 165 employees and generates an annual beer output of 450,000
hectolitres. There have been many innovations during its 175-year
history - including numerous specialist beers and beer-based mixed
drinks. However, one thing has remained unchanged - the original
recipe for the cool and sharp Pfungstädter beer, which has been
passed down from one generation of master brewers to the next.
- A life cycle cost analysis of the brewery's feeding pump
- A detailed report about the findings
- NB 125-200/221 end-suction pump
Cuts operating costs by 39
Feed pumps in breweries often have to run around the clock and
this means that the pumps should undergo regular efficiency checks.
Due to progress in a number of areas, including motor technology,
modern pump systems often achieve greater efficiency and boost
lower power consumption. Replacement of what is to all intents and
purposes, still a fully functional technology therefore often makes
A matter of good
For the technical management of the brewery, Rüttger Stieg,
Technical Director, and Michael Schmitzer, Technical Systems
Manager, it was therefore more or less a matter of good practice
that Grundfos Service did a life cycle cost (LCC) analysis of the
coolant feed pumps: "Obviously, we are constantly on the look-out
for energy-efficient solutions."
Based on the efficiency and energy conditions, the
condition of the circuit pumps for supply of process cooling was
determined by listing the performance-related values. Using
evaluation and calculation software custom-developed by Grundfos,
the values obtained were compared with those of potential new
pumps; the potential savings for each pump were determined for
identical duty points.
A better fit
It quickly became clear that with an efficiency level of 45%, the
performance data for the existing pumps no longer matched the best
technology available and resulted in excessive operating costs. A
Grundfos Series NB 125-200/221 end-suction pump was proposed as the
replacement version. At the desired duty point, the 11 kW pump
achieves an efficiency of 66% (P1 = 6.4 kW).
Compared to the previous pump installation, this offers
potential electricity savings of 92,020 kWh/year (based on 8600
operating hours/year and 23 h/day).
At an energy price of €0.10/kWh, this corresponds to annual
savings in operating costs of €9202/year, or 61% of the operating
costs of the old pumps. Note: The assumed cost of 10 cents per
kilowatt-hour is very low; there is a corresponding reduction in
payback time if energy costs are higher. This reduction also
involves a reduction in CO2 emissions (lignite-generated energy) of
37,176 kg/year (source: the German Federal Environment Agency -
'Climate Change 05/07'). Assuming investment costs of € 3,800
for replacement of one of the pumps, payback of the entire
investment will already be achieved after around five months.
Success was achieved
The recommended pump was installed in Pfungstädter Brauerei in
August 2009. Control measurements showed that the forecasted data
are achieved almost 100%. This project once again shows that
investment in an LCC analysis can identify a considerable savings
potential. "We have to admit that we were very surprised just how
uneconomic the operation of the old feed pumps was. Thanks to the
clearly set-out and well-documented LCC analysis from Grundfos we
had a reliable decision-making basis for our investment in the new
pump," Rüttger Stieg and Michael Schmitzer conclude.