Sustainability report 2017/18

Lean manufacturing: new pickling shop for production and process efficiency

Our Structural Investment project as an example."Relocation of the pickling shop" in Bad Kreuznach clearly demonstrates how important sustainable and efficient production is for KHS.

The large-scale investment project "relocation of the pickling shop" carried out in Bad Kreuznach has come to a successful conclusion after more than four years of intensive work. The entire pickling plant has been relocated and adapted to meet future requirements initiated and supervised by Jürgen Boos, cross-divisional Industrial Engineering Project Engineer. The dip pickling and pickling paste processing facilities were divided into two different areas and connected by underground by pipelines so that they can be operated with only one wastewater neutralization system. The pipelines comply with the latest state of the art: they are double-walled and are equipped with automatic leakage monitoring. In addition, KHS has invested in a new gas scrubber to clean and filter the air in both areas. Dividing the project into two areas shortens the throughput time, which in turn has a positive impact on the carbon footprint.

 

Special floor covering, neutral wastewater

We have added on a new part of a building to accommodate the necessary equipment such as gas scrubbers, blowers, and buffer tanks for wastewater. After an extensive planning phase , we have equipped all treatment areas in accordance with the Water Resources Act with a special plastic floor covering comprised of PE boards all with welded joints and seams to prevent pickling residue from entering the ground. In order to ensure proper wastewater treatment, we have installed a new, two-stage (post) neutralization system.

In order to save energy and lower heating costs, new fast opening and closing shop doors were installed that can be operated remotely from industrial forklifts. The doors thus remain open only for a minimum amount of time when outdoor temperatures are low. Another power-saving measure is brightness-controlled LED lighting. The light output and thus the power consumption is automatically adjusted according to the amount of available daylight.

With the "relocation of the pickling shop" project we underline our holistic expertise in conserving resources in the production process - and additionally apply all legal ecological standards and measures. In this way, we have created a sustainable, future-oriented production area.

More about the idea and project manager Jürgen Boos