Fraunhofer IGCV supports companies in developing sustainable production systems

In view of rising energy prices and declining security of supply, companies are increasingly recognizing the need to make their production and business models sustainable. The Fraunhofer Institute for Casting, Composite and Processing Technology (Fraunhofer IGCV) supports companies in optimizing their production systems both ecologically and economically.

a woman and a man point at a display — Continuous monitoring of energy flows enables companies to produce more sustainably and save costs.

Using energy efficiently

“We help companies, for example, to make optimal use of self-generated electricity from photovoltaic systems or low-price time slots and to increase energy efficiency in production,” explains Vincent Kalchschmid, expert for sustainable production systems at Fraunhofer IGCV. An industry example shows how a company optimized the energy efficiency of several heat treatment furnaces for metal processing. By adjusting the occupancy schedules, unnecessary heating and cooling times were reduced and efficiency was increased. Although this required more personnel and logistics in the short term, the measure significantly reduced energy consumption.

Establishing an independent energy supply

One focus is on the design of the energy supply. Self-generated electricity and energy storage increase supply security and stabilize energy prices. Kalchschmid explains: “First, we analyze all energy flows in the company to understand the interrelationships and derive suitable measures. We use software tools to develop and simulate individual scenarios so that structural adjustments make economic sense.” Depending on the location, building, and production environment, different renewable energy sources may be appropriate.

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Using resources efficiently

In addition to energy efficiency, the focus is on material usage. In many industries, waste can be reduced through organizational measures. A current project at Fraunhofer IGCV is investigating the manufacture of aircraft fuselages: residual materials from composite production will be used for secondary components in the future. “This will avoid large amounts of waste and save material costs – an example of a functioning circular economy,” says Kalchschmid.

Data and testing opportunities as the key

For a successful transformation, companies need transparency and reliable data. Energy monitoring systems help to record consumption and review measures. Kalchschmid also emphasizes: “There is often a lack of opportunities to try out new technologies. Publicly funded projects can make it easier to get started, especially in economically uncertain times.”