Energy audit to DIN EN 16247 for a manufacturer of vehicle bodies and trailers
Hall heating, compressed air and production equipment at an extensive production siteThe client builds trailers and vehicle bodies for cars and trucks. The audit covered a contiguous, leased site with administration, a customer centre, several production halls, and storage and shipping areas.
Audit type
Energy audit to DIN EN 16247-1 under sections 8 et seq. EDL-G
Industry
Vehicle manufacturing: car bodies, vehicle bodies and trailers
Site
One leased site with administration, production halls, storage and shipping
Energy carriers
Natural gas and electricity, fuels assessed at a higher level
Why energy efficiency matters in vehicle manufacturing
Large production and storage halls have to be heated, usually still with fossil fuels. On top of that come electricity-intensive processes such as cutting, machining, extraction and compressed air generation.
Starting with heat generation and cross-cutting technologies cuts energy costs and CO₂ emissions directly and lays the groundwork for a gradual switch to renewable energy.
What was the focus of the audit?
Allocation of energy consumption to consumer groupsWe allocated natural gas and electricity to the consumer groups; hall heating had the largest share. We also evaluated the electricity load profiles and benchmarked the area-related indicators against VDI 3807 reference values.
Fuels for industrial trucks and the vehicle fleet were assessed at a higher level in line with the 90 % rule.
How did the energy audit work?
From the kick-off meeting to the BAFA submission- Kick-off meeting: Define the scope, system boundaries and criteria for assessing measures.
- On-site inspection: Survey of heat generators and of plant, compressed air, ventilation and lighting systems in buildings and halls.
- Data collection and analysis: Evaluate bills, load profiles, inventory and floor-area data; model unmetered consumption to VDI 3807.
- Assessment and report: Derive measures and recommendations, assess cost-effectiveness using the net present value method, point out suitable funding programmes and prepare the energy audit report.
- Completion and BAFA submission: Online submission to BAFA and closing meeting with the organisation.
What made this audit special?
Conditions that shaped the approach and the resultExtensive site
Numerous halls of different use, construction and age, plus several grid connections, had to be consolidated and assessed individually.
No sub-metering
Electricity and heat were not metered downstream. Allocation to consumer groups was based on modelling, inventory lists and consultation with the plant.
Hall heating
We looked separately at heat losses and load curves caused by large room volumes, door areas and seasonally fluctuating loads.
Ongoing modernisation
The envelope of the leased building was outside the audit scope. Completed and planned measures such as heat pumps, photovoltaics and radiant ceiling panels were included in the assessment.
Project profile
| Audit type | Energy audit to DIN EN 16247-1 under sections 8 et seq. EDL-G |
|---|---|
| Industry | Vehicle manufacturing: manufacture of car bodies, vehicle bodies and trailers |
| Focus areas | Hall heating, hot water, production plant equipment, compressed air, ventilation and lighting |
| Possible additional reviews | Load profile analysis, energy indicators benchmarked against VDI 3807, cost-effectiveness analysis using the net present value method, review of funding options, assessment of compressed air generation, classification of requirements under EnEfG, EnSimiMaV and CSRD |
More energy audits by INOPCO
References from industry, retail, IT and healthcare
IT service provider with data centre
Electricity consumption of servers, air conditioning and offices broken down across two leased sites, with separate indicators for server and office space.
Healthcare: specialist hospital
Heat supply with a CHP unit, medical equipment and listed buildings at four sites, assessed during ongoing hospital operations.
Retail: nationwide branch network
Multi-site procedure with clustering, a model branch and representative inspections across all sites and energy carriers, including the vehicle fleet.
Chemicals: modified starch production
Process steam, production machinery and historic buildings in continuous shift operation, with load profile analysis and a review of on-site power generation.