Alfa-Plam produces stoves, cookers and boilers, used for cooking and heating with mostly woods or pellets on household level. By producing roughly 160,000 units per year with a staff of 1,000 people, they are the market leader in Serbia and among the top five producers in Europe. Alfa-Plam sells its product on the domestic market (35%) and the European markets. The main export markets are the ex-Yugoslavian Republics Bosnia and Herzegovina, Macedonia, Montenegro, Slovenia and Croatia followed by Germany, Italy, Austria and Poland.
Ana Stefanović and Igor Radulović attended the Energy Scout trainings of the German-Serbian Chamber of Commerce and went back to their factory to apply their newly gained knowledge on how to save energy and resources. Realizing that the biggest energy savings can be obtained most likely from the production process itself, they joined their colleagues in charge of paintwork and “scouted” for efficiency potential.
The painting work is divided in two processes. First the products must be degreased and washed in a wet process before the painting. Then the painting itself is done in a second production line, followed by a drying process, where the paint is baked on the surface. On both lines, a considerable amount of energy is spent on heating: the detergent for washing metal positions and the dryer for baking the paint.
Therefore, the simplest thing was to reduce the temperatures in the process. That is why the testing of a new detergent, working well at lower temperatures, proposed by Alfa-Plams technologist Milena Jovanović was immediately started. The results the Energy Scout received from the tests were impressive. In particular, because they had the chance to implement the new solution for another three similar productions lines, therefore quadrupling the saving potential. The core of the project was to use a new detergent solution which allows
a significant reduction in the operating temperature in the pretreatment process – from 60⁰C to 35⁰C.
This saves 524 MWh of electricity per year for heating purposes, cutting CO2 emissions by 475 tons per year (lots of coal plants on the grid) and saving 58,000 € on electricity costs. The investment costs of 2,580 € pay off after only 15 days! The incredible fast return on invest time was the main reason for the Serbian Jury to award the third place as “Energy Scouts of the Year” to Ana and Igor.
Process optimization
- Industry sector: metal processing
- Energy source: electricity
- Energy savings potential: 524 MWh/year
- CO2 savings potential: 475 tons CO₂/year
- Potential cost reduction: 58,000 €
- Investment costs: 2,580 €
- Payback period: 15 days
- Company:
ALFA-PLAM D.O.O.
Radnička 1
17500 Vranje
Serbia
https://www.alfaplam.rs/
