Case Study on Ytong building material Manufacturer Xella

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Xella International GmbH is a corporate group with head office located in Germany. Their main profile is manufacturing and marketing building materials, gypsum fibreboard and cement-bonded dry lining panels together with lime and limestone. The following case study was completed for one of Xella’s Eastern European centers. The aim was to provide a hands-on energy management system solution for the production of Ytong building material.

The process involved the assessment of the current situation, discussing the potential new energy efficient technologies and measures, setting objectives on energy savingscarbon dioxide savings, weighing up the investment costs, operation and maintenance costs for each production line, unit and finished product The client was particularly interested in knowing the exact energy consumption and therefore cost per product, which was easily achievable by using AVReporter Energy Management Software.

The main energy management software requirements were:

  • XELLA requested an Energy Management and Monitoring system, which is capable of keeping track of their consumption at specific measurement points.
  • These measurement points are mostly related to the production. The measurements contain gas, electricity, heat and water consumptions.
  • Allowing users to create their own customized consumption reports, tendency analysis on the web, without the installation of any software to the users’ computers was also an important factor.
  • End-users should be able to access information on the web without the need of installing any software to their PC.
  • Finally XELLA requested automatic report creation based on their daily, monthly and annual energy consumptions.

About the Energy Management System’s structure:

  • Establish optimum communication with different type and make of field power meters, logging their historical data into database for later analysis.
  • Three PLCs (Modbus TCP/IP compatible through Ethernet) were used as gateways collecting the consumption data of gas, heat, compressed air and water meters. These three PLCs are connected to the server.
  • The system also contains a GPRS modem for power plant heat measurement.
  • Integration of virtual AVReporter server equipped with AVReporter Lite Edition and Webpublisher

Energy management system in Ytong

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  • VEOLIA- Energy Management Solution for utilitiesVeolia is one of the market leader companies in Hungary in the energy, water and waste management industry. The group company employs approximately 2,500 people who provide professional services to various towns, institutions and industrial companies enabling them to efficient manage resources, while the water utility and district heating branches of the company supply drinking water to hundreds of thousands of families, and heat to tens of thousands of households. With its more than 20-year professional experience Veolia is a determining participant of the Hungarian energy market. The energy branch of the company group provides energy to various institutions of 50 local municipalities, 85 state-owned and public buildings, 30 health institutions and 31 industrial plants, while its district heating networks supply 67,000 residential and institutional customers nationwide. In the three power plants of the company operate high-efficiency natural gas blocks and blocks utilizing renewable energy (biomass).
  • Meet us at the Utility Week in BarcelonaThe European Utility Week aims to be a serious information platform connecting the smart utility community, focusing on regional and global developments in Grid Optimisation, Renewables, Energy Storage, Smart Metering, Smart Cities, Smart Homes, Energy Services & Efficiency, Intelligent Buildings, Data Management, Analytics and IoT, Cyber Security, Smart Gas and Smart Water.  The event serves as an annual meeting point for the community and will be attended by 12.000 international visitors, 450 speakers and 600 exhibitors. 
  • Remote Desktop ServiceAs part of our sales support options, remote desktop service is high on demand.
  • AVReporter Windows Phone & IPhone Mobile Client (Remote Meter Reading)With the support of this application the measurement data (identifying meters manually or by QR code) can be entered and sent via email (attachment in CSV file format) easily into the AVReporter server application.  
  • Technical SpecificationsBelow are some of the specific key elements of AVReporter: