We use energy sensibly - Oni

We use energy sensibly
Gealan reduces energy costs, using
ONI technology!
Figure 1 Energy-saving cooling system technology at the Gealan Tanna site

Preface
We use energy sensibly
In 47 countries of the world plastics processing companies rely on the
trusted and energy-saving system technology from ONI at Lindlar,
including, for years, the Gealan group which operates in the plastics
processing industry successfully and is expanding.
Currently, the latest production plant for window sections is installed in the
Russian Novosibirsk. From there, the Russian market is to be supplied with
high-quality products. For this production plant as well Gealan relies on the
energy-saving system solutions from the ONI specialist at Lindlar to keep
the operating costs as low as possible.
Continuous success
Gealan is an internationally successful and expanding plastics processing company with
product sites in Germany, Poland, Rumania, Lithuania and a licensed production in Russia. This
continuous success of the company is based on innovative power and absolute cost
management.
However, Gealan cannot entirely evade the partially dramatic development of energy and raw
material prices, but relies on cost-saving process and system technology which eases the cost
pressure. In the area of cooling power supply the company has for years been using energysaving
and reliable ONI system solutions which keep the operating costs as low as possible.
From the planning to turnkey cooling water supply and heat recovery systems everything is
provided by one company for using cost-free waste heat for heating!
Therefore, the new plant in the Russian Novosibirsk has relied on efficient energy and process
engineering from the beginning, an indispensable requirement for an economically successful
and competitive production site.
Figure 2 Final installation of a container centre Figure 3 A container-type cooling system for the new
plant in Russia is loaded.

We use energy sensibly
More than 70 % of the operating time without the use of a chiller
Cooling power generated by chillers is expensive. Therefore, Gealan uses chillers for the
generation of cooling power only during the warm months of summer and a short transition
period. For more than 70 % of the operating time the use of chillers is dispensed with, saving
much energy and thus operating costs for electrical power. Draining outdoor coolers as a socalled
winter relief provide cooling power for the cooling reservoirs during the transition period
and winter time, reducing electric power to a value of approximately 2 – 3 % of that of a chiller.
The plant management is performed by a dynamic control system developed by ONI, using
energy-optimizing system software to ensure that low temperatures are generated at the lowest
possible power at any time.
Just with regard to increasing power costs this energy concept is forward-looking.
Cost-free heating power
A company having several thousand square meters of production, office and storage space
requires a heating centre providing several hundred kilowatts of heating power. The
consumption of heating power alone and the resulting operating costs are not insignificant and
strain the entire cost situation.
Therefore, Gealan employs a special ONI system solution which uses the exhaust air from the
hall for heating a neighbouring logistics centre. In practical operation this technology supplies
cost-free heating power from the waste heat or hall exhaust air to 21,000 m² of hall space at
one site. This type of using waste heat has an interesting double benefit with a financial
advantage for the operator. Waste heat which was a burden for the production area till then is
cooled by the ONI system. The waste heat thus generated becomes cost-free heating power
which replaces primary energy carriers such as fuel, oil or gas. Thus, this ONI technology is
especially valuable in times of rising energy costs.
Figure 4 ONI air heaters heat hall areas, using cost-free waste heat

ONI-Wärmetrafo GmbH
Chilling, air-conditioning,
temperature control technology
Niederhabbach 17
51789 Lindlar
Phone +49 (0) 2266 4748-0
Fax +49 (0) 2266 3927
E-mail info@oni.de
Internet www.oni.de
We use energy sensibly