As you know, Berlinger's commitment to sustainability is more than just a promise. Facility Manager Jürg Bähler reveal the innovative steps taken to reduce energy costs and environmental impact, demonstrating leadership in green technology and sustainable practices – by implementing an innovative ice heating system.
The Beginning: Challenges and High Costs
At Berlinger, sustainability isn't just a buzzword; it's a core part of our company's ethos. With the help of Facility Manager Jürg Bähler, Berlinger embarked on a small but innovative journey to reduce energy consumption at the production and office building and set an industry benchmark.
“Since the facility opened in July 2013, we've faced several challenges with our energy systems”, explains Jürg Bähler. The original heating system, which used ice heating technology, presented numerous operational difficulties. “Despite the innovative concept, the system didn't initially work as intended, resulting in high gas consumption and costs”, he recalls.
The Turning Point: A collaboration with a leading Swiss company
Recognizing the need for a sustainable solution, Jürg Bähler turned to a leading Swiss company in building management systems. “Their expertise was instrumental in transforming our energy setup”, he says. The collaboration involved extensive work, including the removal of several hundred meters of incorrectly installed cables and a comprehensive system overhaul.
Achieving Efficiency: Reduced Gas Usage
By the first quarter of 2020, the revamped system had drastically reduced gas consumption by more than 40 times to just 92 cubic meters, resulting in significantly lower costs. “This is in strong contrast to what we used to spend”, recalls Jürg Bähler. “It shows a significant financial and environmental benefit.”
How Heating and Cooling with Ice Storage Works
The innovative ice heating system uses two large underground ice reservoirs, one with 220m³ and the other with 160m³ of water. These reservoirs cool the building in summer and heat it in winter. “We use the energy stored in the ice to regulate the temperature of the building, achieving remarkable efficiency”, explains Jürg Bähler. Despite the initial hurdles, the system now works seamlessly and provides a model for sustainable industrial heating.
Expanding Sustainability: Transition to LED Lighting
In addition to the ice heating system, Berlinger has made significant strides in reducing electricity consumption. “We replaced all the neon lights with LEDs, which resulted in significant energy savings”, says Jürg Bähler. This transition to LED lighting was carried out smoothly, even in a live operating environment, and has resulted in the company being 90 percent LED today.
The Project in Numbers
- Ice Reservoirs: 220m³ and 160m³
- Gas Cost Reduction: Cost savings in the four-figure range
- Gas Usage Reduction: From 4.000 cubic meters to 92 cubic meters per quarter
- LED Transition: 90 percent of the facility now uses LED lighting
Continuous Improvement: Automation and Employee Engagement
For Berlinger facility manager Jürg Bähler “the continuous improvement of our facilities is crucial. We’ve also introduced automatic dimming and shut-off systems for lights, which significantly cut down unnecessary energy usage.”
But Jürg Bähler’s commitment extends beyond technical upgrades. They actively foster a culture of sustainability among employees as well. “There’s a growing awareness and personal accountability among our staff regarding energy conservation”, Jürg Bähler observes. This shift is partly driven by rising energy costs, making employees more conscious of their consumption both at work and at home.
Whats Next for Berlinger? Charting Sustainable Futures
The success of this project has not only reduced Berlinger’s carbon footprint but also inspired further green initiatives. “Looking ahead, we aim to explore additional sustainable energy options, despite the challenges we may face. This forward-thinking approach ensures that Berlinger remains at the forefront of sustainable innovation.