Matal s.a.

Energy Management and Optimization

in Refrigerating Plants

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GEA Group
Leading technologies in mechanical and plant engineering

Since 1881. International group

17 500 employees
Euros 4,5 billion sales
Air Treatment, Process Equipment, Mechanical
Separation, Dairy Farm Systems, Energy Technology,
Process Engineering,
Refrigeration (contracting & manufacturing companies)

KBA , GOEDHART
Evaporators, Condensors

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GRASSO
Piston and screw compressors

REVALCO
Valves

MATAL Energie - MNA 18 06 2007

GENEGLACE
Flake ice generators

MATAL s.a.
Adapted solution for your refrigeration process needs

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Since 1938
Contracting company in GEA R-Division
350 employees
Food processes dedicated teams
Service network close to your installations

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MATAL Energie - MNA 18 06 2007

MATAL s.a.
35 agencies on french territory

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MATAL s.a.
Present throughout the chain of your refrigeration needs
DESIGN

EXECUTION

IMPROVEMENT

MAINTENANCE
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Context
Energy saving in refrigeration: an important stake

Energy cost increase: + 30% since 2005

In the last years, priority was given to investment cost to the
detriment of energy performance

New products, load variations on process lines not integrated in

control command loops

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Customers concerns
A recent awareness

Reduction of operational costs

Respect environment
Increase the value of refrigerating production in process
performance

Benefit from a flexible and reactive production tool

Ensuring product quality
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Solutions in energy management

Market offers

Energy supplier contract management: ON/OFF actions

Manual modification of control command parameters

Sporadic decreasing of energy

consumption
but passive solutions

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MATAL Solution
DIAGNOSTIC
APPROACH
P
RE
G
TIN
OR

TA
I LO
PR ROJ MA
EC DE
T

Support our customers in optimization process

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IM
SO PR
L U OV
TI EM
ON E
S NT

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FOOD SAFETY

FI
ND

IO
AT
ER T
IG R
FR XPE
RE E

CUSTOMER

MATAL Energie - MNA 18 06 2007

Energy module made in MATAL

ENERGY

PLC

PLATFORM

REFRIGERATING UNIT + END

USING

ON PC
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REFRIGERATING
PLANT

Online energy optimization

Analogy with car driving: anticipation & adaptation
Anticipation in
front of way
changings

Obstacles
management

Integration of
external
environment

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Control of
effects resulting
from actions

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MATAL Method
1.1.SETTING-UP
SETTING-UP
ENERGY
ENERGYModule
Module

2.2.DIAGNOSTIC
DIAGNOSTIC
ACTION
ACTIONPLAN
PLAN
(6 months to 1 year)
(6 months to 1 year)

Installation
Installationaudit
audit
Recording
and
Recording and
analysing
analysing

Identification
Identificationofof
sources
sourcesofofgain.
gain.
Actions
description
Actions description

RESULTS
RESULTSCHECKING
CHECKING
(6 months to 1 year)
(6 months to 1 year)

ONLINE PILOTING in operation

ONLINE PILOTING in operation

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Evolution
Evolutionofof
indicators
indicators
New
Newpiloting
piloting

MATAL Tool
Assets :
Developed by experts in refrigeration
Adapted to each process
Easy interface with industrial PLCs
Respect of running conditions range (compressors)
Integration of product quality indicators
Quick return on investment
+:
Recording and display of external process line parameters

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Success factors
Collaboration between actors: Customer + Matal
Refrigerating
process user

PASS &

MATAL
agency

GPS

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Field experiments

Case 1: Brewery
Case 2: Milk factory
Case 3: Cold storage and freezing tunnels

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1- Brewery
8% of COP Gain

27200 annual saving on energy invoice

TOD

Machinery room N1 TOD NH3

NH3 Pump
Distribution

NH3 Unit

Bche

Machinery room N2 TOD MPG

TOD

NH3 Unit

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Primary MPG
loop

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Secondary MPG
loop

2- Milk factory
10% of COP Gain

20500 annual saving on energy invoice

Online COP optimization

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3- Cold store and freezing tunnels

20% of COP Gain

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26000 annual saving on energy invoice

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MATAL engagement
Engagement on gain results
Study of existing
plant

Technical and
commercial offer

Matal support in
refrigerating plant
management and
improvement

Follow up
Progress plan
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Matal Energy steps and planning

step 1
Setting-up

Online optimization

Reference period - Analyse

er
rd
O

ng
di
r
o
ec
R

:
P n
O atio
C iz + nt
r
tim ffe me
op o ge ain
ga g
en on

ENERGIE Platform rent

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step 3

step 2

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Mois