The core activity of Certa Kft. is the manufacture of high-precision aluminium and zinc components, covering the full process from casting design through tool making, casting, machining and surface treatment to assembly.
Results
In the company's electroplating hall, operators faced three main problems. First, the processes carried out there released significant quantities of plating fumes and metal dust, which is unfavourable both for employees and for the products. Second, owing to the internal heat loads installed in the hall, indoor temperatures were extremely high during the summer. The third problem arose from high gas consumption, caused by the outdated dark radiant heating system used in winter.
The solution therefore had to address ventilation, cooling and the modernisation of the heating system alike.
As part of the project, two IntrCooll Plus units were installed, equipped with heat recovery (HR) and fan modules, as well as a heating coil and filters on the recirculation branch. The system is capable of completely replacing the indoor air volume up to 15 times a day, providing fresh, clean air in the hall and removing plating fumes and metal dust. Heat is discharged by gravity through six open louvres, while the heat source is the oil heat of the existing compressor system, which we were able to use for heating via the heating coil mounted on the HR module. The system maintains an indoor temperature of 26 °C in summer and 22 °C in winter, with humidity of no more than 60%.
The integrated PLC also enables intelligent control of cooling and heating. Control settings can be adjusted precisely, in line with the most favourable parameters, so that operation requires the lowest possible energy consumption. The sustainability of the solution is further enhanced by the use of 100% recovered waste heat for heating, which has allowed us to reduce the energy demand for heating dramatically as well.
For the investment as a whole, we were moreover able to secure approximately HUF 25 million in corporate income tax (TAO) relief for our client, further shortening the payback period of the solution.
