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Marcheluzzo S.p.A.: Centralized Thermal Energy Generation for Sanitaryware Production at KOHLER Company

In today’s ever competitive world – fuel consumption is a considerable and ever-increasing share in the final costs of the finished product, with energy efficiency, combined with maintenance costs being the main areas of concern for the owners of sanitaryware factories. Thermal energy generation and its control are an important aspect in the design and management of today’s modern sanitaryware factories – the process for which energy is required, is a point that needs particular attention in view of both economic savings, cost control and, above all, respect for the environment

The modern sanitaryware factories of today, have equipment, plant and machinery that require thermal energy: among them the kilns, dryers and pre-dryers, conditioning systems of the casting rooms and the pre-drying areas, slip heating, and the utilities for staff and personnel (bathrooms, offices etc.).

The solution studied by Marcheluzzo, thanks to its expertise and experience in the field of thermal heat production and distribution, is that of a centralized arrangement with the thermal power plant as a system. The term centralized system illustrates a solution in which heat is generated in a well-defined and specific area of the factory. The thermal power plants generated energy is distributed to the various users in the form of a fluid at a certain temperature through a precisely dimensioned and calibrated system of pipes.

Marcheluzzo’s  centralized system provides all users with the energy using a hot fluid in a piping system as the energy source – which this is used in conjunction with air flow. Therefore, there will be numerous water/air exchangers (radiant batteries) installed on the systems upstream or downstream of the fans. The thermal power plant has the calculated capacity to produce hot water in calculated quantities that depend on the process and users energy needs, the water is brought to a temperature of 90 °C or, if required, to a temperature of 120 °C. The case study of the project is presented in detail in cfi 11-12/2020 and offers an useful insight to companies considering investments in a new factory or in the expansion of an existing plant.

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