Company

Mader GmbH & Co. KG

Information

Mader is a company who cares about energy and resources as well as cost saving throughout the whole process chain for compressed air. Based on many years of experience in compressed air supply as well as compressed air control and application, we are in the position to offer services and products for the whole compressed air process: from compressed air generation (compressors) and transportation (tubing system) to application (pneumatics).

In the area of compressed air, due to an intelligent energy management, energy consumption can be reduced significantly. We analyse the complete compressed air process and offer solutions to our customers – taking into account the best energy and cost efficiency possible. Energy efficiency of compressed air systems can be significantly increased by choosing the right compressed air system, the use of intelligent control systems and energy saving components, permanent leakage control and monitoring of the entire system. This also implicates a reduction of power consumption and CO2 emissions.

For compressed air generation, we support our customers with a complete, customised, modular designed service package. This includes conception, realization and commissioning of compressed air stations as well as implementation of all maintenance and repair work. Continuous monitoring ensures the optimized process and saving sustainably. As a result, possible weaknesses can be recognised and improvement measures can be introduced, if necessary.

As a producer of high quality pneumatics Mader offers a variety of solutions in the handling technology, drives, compressed air preparation and components. The company is specialised in customer specific product requirements and the optimisation of purchase processes. Focus is on intelligent and cost-effective design from quotation phase until goods receiving for each customer.

Services

COMPRESSED AIR AUDIT ISO 11011

To analyse the efficiency of the whole compressed air system, a compressed air energy audit is performed. The audit consists of three major parts: initial consultation, in-depth analysis and consultation for implementation. During the initial consultation a rough assessment of the existing weak points and the optimisation potential is made.

The in-depth analysis shows the customers reliable data for optimisation potential. A detailed action plan with recommendation for actions and a customer-specific, vendor-neutral compressed air concept is developed. The results are summarised in a detailed report and can be used for the energy management system (i.e. ISO 50001, DIN EN 16247-1 and EMAS). The report serves as a decision support for the customer, with commercial and technical respects.

http://www.mader.eu/fileadmin/download/AirXpert/MADER-Bescheinigung-DIN-EN-ISO-11011.pdf

http://www.mader.eu/mader-airxpert/

LEAKAGE MANAGEMENT

Compressed air consumption can be reduced substantially by continuous leakage management. Leakage location, covering the whole compressed air system, can be carried out with a detection device. Location can also take place during operation. The leakages identified are marked, numbered and photo-documented. Additionally, an economic classification of the leakages can be carried out, i.e. how much is the air loss for which leakage. Thus, energy saving potential can be described in l/min, Euro and CO2. A prioritisation for leakage repair can be done.

Additionally, we carry out a professional elimination of leakages.

http://www.mader.eu/leistungen/leckagemessung/

PNEUMATIC PRODUCTS

Ensuring energy-efficient compressed air supply – from generation and preparation and distribution up to application with energy-efficient pneumatic products. Our integrated approach guarantees the optimal alignment of the whole compressed air system.

http://www.mader.eu/produkte/pneumatik/

Projects

REALISATION OF AN ENERGY-EFFICIENT MASTER PLAN

At a customer in the packing machinery industry, based on the data analysis, a master plan has been realised. By using a new variable speed compressor, reducing the network pressure by 2 bar and the installation of a heat recovery, a yearly electricity cost saving of 43,234.00 € as well as a heating oil saving of more than 10,000 liters. The investment was 24,900.00 €, payback period 0.6 years.

SAVING FROM CUSTOMERS

In 2013, due to optimisation in the area of compressed air (leakage location and removal, heat recovery and optimisation of the whole compressed air system), with our customers altogether we were able to achieve energy savings of around 769,473 kWh (474 tons CO2) in total. In 2014, by implementing our solutions, an energy saving of 1,330,540 kWh and a CO2-reduction of 820 tons was achieved by our customers.

Here you can find an example of implementation

http://www.mader.eu/fileadmin/download/anwenderberichte/Der-Betriebsleiter-Mader-Druckluft.pdf

INSTALLATION OF A VARIABLE SPEED COMPRESSOR

By installation of a variable speed compressor, energy consumption of a customer in the beverage industry has been reduced by 120,300 kwh per year. The related electricity cost reduction amounts to 18,045.00 €. Invest was 20,850.00 €. Additionally, the customer has received an allowance of 30 % of the investment cost, out of the BAFA funding programme "Hocheffiziente Querschnittstechnologien" (“Highly efficient cross-sectional technologies”).