gwk cooling systems

Energy saving is fun – an intelligent composite system reduces energy costs and the CO2-consumption
gwk cooling systems – the key to greater energy efficiency


As far as cooling is concerned the trend is going towards higher savings of operating costs for cold water production and increased use of waste heat for heating processes. The per-manently increasing costs for heating oil, gas and electric energy in combination with a more restrictive EU-legislation enhance the cost pressure on processors in a way that more often precise requirements are made how much electric energy may be used for the production of one kilogram plastic material. Such demands can only be fulfilled by tailor-made compound systems with integrated energy saving modules.


On the occasion of the Fakuma 2014 gwk presents the actual state of the art of these com-pound systems that distinguish themselves from other systems by a particularly high energy efficiency. In this connection all process requirements regarding demanded temperatures and water quantities with a minimum energy consumption at the same time are fulfilled. For production this means that temperature controllers and cooling plants can be operated in a well-coordinated energy compound system.


Of course, environmental aspects are taken into consideration here as well. So, for nearly 20 years gwk has used the highly efficient refrigerant R 134a, that is chlorine-free and has no ozone depletion potential. The system pressures that are low in comparison to other refriger-ants reduce signs of wear and increase the working life of the components in the refrigerant circuit. Recalculated and technically modified evaporators and condensers as well as ener-getically optimised screw compressors with improved control concept lead to another capaci-ty improvement. So, the maximum energy efficiency of the complete system can be reached and a major contribution to the reduction of CO2-emissions is made.


Central component of the innovative cooling systems are the new gwk SKL and SKW water chillers, that have an energy efficiency factor of up to 10 in full load operation, i.e. with 1 kW electric capacity 10 kW cooling capacity are produced. Out of the wide range of water chillers a water-cooled chiller with a capacity of 600 kW cooling capacity is presented by means of which energy savings of up to 160.000 kWh electricity per year can be made.


gwk hermeticool cooling systems use the differences of night and day temperatures as well as those of the seasons in order to produce cold water for production facilities in a cost-effective manner. Here the running time of the water chiller is reduced to a minimum. Sophis-ticated energy-saving modules to control the refrigerant flow and motor speed in dependence on the ambient temperature and load, notably increase the efficiency in comparison to con-ventional systems. By means of the proven gwk-motor management the actual power con-sumption of the fans is continuously monitored and adapted to the capacity demands via speed control, so that the lowest energy consumption is always attained. These new motors with a high efficiency rate in comparison to conventional technologies can be operated with an extremely low rotational speed, so that – in combination with the optional night time temperature reduction – a major decrease of the sound level can be achieved. The individual operating parameters of each motor can be stored and in case of an eventually required motor exchange, be reintegrated in the comfortable motor control system. By means of different installation examples gwk shows, how operating costs can be reduced by up to 85 % compared with conventional cooling systems.


Components of the gwk energy recycling system like the use of the return water from the hydraulic cooling of injection moulding machines for heating purposes via a low-temperature underfloor heating and via heat transducers are presented on the basis of corresponding installations. In addition gwk shows a representative selection of components that are neces-sary for an efficient water treatment in terms of actual filter technology up to a central water treatment system.


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