Smart Heating – intelligently reduce energy consumption

After entering the desired start time, Smart Heating automatically ensures that the temperature of the process media is within the defined operating window at that time. This helps to avoid energy- and cost-intensive standby phases after operational interruptions.

In addition to controlling the temperature of the process media, the intelligent heating control also manages the activation of auxiliary units such as a extraction system in series drying systems. This also contributes to energy savings. (Image source: Karl Roll)

With Smart Heating, the cleaning system manufacturer Karl Roll has developed a solution that intelligently controls the heating of process media in cleaning systems. It ensures that the system is ready for operation at the scheduled time after interruptions – without energy- and cost-intensive standby phases due to safety time buffers.

Whether solvent-based or aqueous cleaning, to achieve a requirement-oriented result, the temperature of the process media must be within a defined working window. In the case of a solvent system operated with flammable hydrocarbons above the flash point, it must also be ensured that units such as vacuum pumps and cooling are switched on depending on the temperature. In the case of an aqueous cascade rinsing system with open baths, extraction is used once a certain temperature is reached. Both the heating and auxiliary units are among the main energy consumers of a cleaning system.

High energy losses due to unnecessary standby times

To ensure that the system is ready for operation after an interruption, for example overnight, over the weekend, or during a holiday, an employee sets when the heating should start warming the media. This start time for the heating is usually determined based on experience and with a generous safety margin. As a result, it is not uncommon for standby times lasting several hours to occur, during which the process media are kept within the specified temperature window without any parts being cleaned. The energy required for this unnecessary heating of the media and, if applicable, operation of auxiliary units quickly adds up to a consumption in the lower four-figure kilowatt-hours range over the course of a year.

Intelligent heating control minimizes energy consumption

Aside from the additional financial costs for the plant operator, such energy losses are incompatible with efforts to reduce CO2 emissions and meet climate protection goals. For the cleaning system manufacturer Karl Roll, this was the motivation to develop the intelligent heating control Smart Heating.

Based on the information about when the system should be ready for operation, the patented Smart Heating independently determines when to start heating the process media. Sensors continuously measure the temperature of the process media. The recorded values are linked and processed with stored algorithms. The control system "knows" when the heating must be started so that the process media reach the defined temperature exactly at the scheduled start of operation. This eliminates the energy-consuming and costly standby phases with safety time buffers.

At the same time, Smart Heating creates a dynamic heating curve that reflects the condition of the heating system. This allows the control to detect whether the heating element is functioning correctly. For example, if a heating rod fails or the performance is reduced due to deposits, this is automatically compensated so that the system is still ready for operation at the scheduled time.

In the future, Smart Heating will be one of the optional features for all Roll cleaning systems. Additional functions will be integrated depending on the system, such as regulation of vacuum and cooling technology for solvent systems operated with flammable hydrocarbons or extraction systems for aqueous cleaning systems.

Existing systems can be retrofitted with this technology in some cases. A key prerequisite is that the system control still has sufficient capacity to integrate the function.

Karl Roll GmbH & Co. KG will be exhibiting at parts2clean in Hall 9, Stand A05.