Future-proof and sustainable production - thanks to efficient refrigeration technology

Moving away from fossil fuels: this is one of the key sustainability goals of the Burger Group from Schonach in the Black Forest. The long-established specialist for drive solutions is consistently focusing on environmentally friendly technologies. The new technotrans cooling system for the manufacturer's injection molding production is a key component of this approach. It replaces the existing system and is a future-proof investment, not only because it uses the natural refrigerant R290 (propane).

KBS Spritztechnik GmbH

KBS-Spritztechnik GmbH, a Burger Group company, specializes in the production of precision injection-moulded parts made from engineering plastics. It mainly produces components made of polyamide, POM and PBT, partly using two-component injection molding and in combination with liquid silicone (LSR). Special attention is paid to the production of hybrid components, in which turned or stamped parts from the company's own production are overmolded.

Over 95% of the products manufactured are used within the Group, which is active in various sectors such as mobility, medical technology and building technology. With more than 50 injection molding machines, including high-precision hybrid machines, KBS-Spritztechnik offers innovative solutions for demanding customers. Another focus is on the development and integration of efficient thermal management systems to ensure the highest quality standards in production while promoting sustainable, energy-efficient solutions.

Task// The Burger Group from Schonach was faced with the challenge of modernizing its existing refrigeration technology for injection moulding production in order to avoid downtime, increase efficiency and achieve its sustainability goals. The aim was to implement a future-proof and environmentally friendly solution that would meet the increasing demands of production and replace fossil fuels. The implementation required precise planning in order to continue production without interruption during the conversion. Innovative approaches and close collaboration resulted in a solution that optimally combines efficiency, sustainability and operational safety.

      Tobias Escher (left), Sales Manager Cooling
      Solutions at technotrans, and Matthias Fehrenbach,
      General Manager of injection molding production 
      at the Burger Group in Schonach

Demand of engineering expertise

Engineering// The Burger Group chose technotrans as its partner because of the company's comprehensive engineering know-how and high level of vertical integration. technotrans realized the project from the initial planning to the turnkey installation from a single source. A key aspect of the cooperation was the ability to flexibly implement the Burger Group's individual requirements.

technotrans also demonstrated its strength during the implementation phase: two rental systems ensured smooth production operations and all work - from installation to commissioning - was carried out on time and with the utmost precision. technotrans combines technological expertise with practical solutions, making it a reliable partner for future-proof thermal management solutions.

Innovative cooling concept for maximum efficiency and sustainability

Implementation// technotrans has developed an ultra-modern and environmentally friendly solution for the Burger Group's cooling concept. The innovative cooling technology is based on two main components: a compact chiller and a heat pump. The chiller uses the natural refrigerant propane (R290), which is not only particularly environmentally friendly but also highly efficient. The heat pump uses the surplus energy from the return water and feeds it into the system to heat the building, thereby reducing the use of fossil fuels.

The entire system is equipped with an energy-saving module and an electronic expansion valve to optimize the cooling capacity and significantly reduce operating costs. The technotrans cooling concept thus ensures that the Burger Group remains at the cutting edge of technology in terms of both energy efficiency and sustainability.

Operating cost savings: 25 %

Optimized cooling system

One cooling circuit replaces dual-circuit system

technotrans has developed a new single-circuit system for the Burger Group that replaces the previous two cooling circuits. The temperature control was adapted to a constant flow temperature of 25 °C, which results in lower operating costs, higher efficiency and a longer service life of the free cooler.

The new system uses pure water instead of a water-glycol mixture, which both improves heat transfer and meets the requirements of the Water Resources Act. In addition to supplying the 50 injection molding machines and temperature control units, a hermeticool cooling system provides passive free cooling. In summer, the cooling is supported by a compact chiller. Thanks to the technotrans energy-saving module, the operating costs are reduced by around 25 %.

By switching to the single-circuit system, technotrans was able to implement a more efficient, sustainable and future-proof solution.

Innovative solution concept

Underground cold water tank

In the course of modernizing the refrigeration technology, the Burger Group and technotrans opted for an innovative solution: the integration of an underground cold water tank. The original plan was to place all the refrigeration technology components in a technology container on the roof of the building. However, Thomas Burger, Managing Partner of the Burger Group, came up with the idea of installing the cold water tank underground. Implementing this idea had several advantages. The 8 cubic meter tank, which was installed on a concrete foundation, uses the constantly low ground temperatures to support the cooling capacity. This means that the overall performance of the cooling system can be made more efficient, which reduces operating costs. In addition, the underground tank does not take up valuable production space and, with a capacity of 6,000 liters, offers stable temperature control.

»If the cold water tank is installed in the ground, the temperatures prevailing there can support cooling and save cooling capacity.«

Thomas Burger
Managing director of Burger Group

Shaping the future:
Focus on sustainability

A step towards sustainability

Integration of return energy

The Burger Group consistently pursues the goal of eliminating fossil fuels from its processes. The new technotrans cooling system is a pioneering project that focuses on energy efficiency and sustainability.

A particular focus is on the integration of return energy. The energy released by the return water from the injection molding machines is not left unused, but is used specifically to heat the building complex. A heat pump developed by technotrans was installed for this purpose, which raises the temperature of the return water to around 60 degrees Celsius. This heat supports the central heating system, which is currently still partly dependent on gas heating.

In the long term, however, the Burger Group plans to completely dispense with fossil fuels.

Away from fossil fuels

Use of natural refrigerants

As part of the project for the new cooling system of the Burger Group, technotrans relies on the use of natural refrigerants in order to minimize the environmental impact while maximizing the efficiency of the cooling system. Propane (R290) is used for the heat pump and the compact chiller - a naturally occurring refrigerant with a particularly low Global Warming Potential (GWP) of just 3.

For the Burger Group, the use of R290 is a future-proof decision. The use of this natural refrigerant not only reduces the CO2 footprint of the cooling technology, but also ensures the long-term legal compliance of the system. This decision supports the Burger Group's long-term goal of achieving sustainable production without the use of fossil fuels and environmentally harmful refrigerants.

»Whether it’s the PFAS discussion or the F-gas Regulation, propane ensures compliance for the coming years. Our investment is future-proof«

Matthias Fehrenbach
General Manager of KBS-Spritztechnik GmbH in Schonach

More than half of the 50 injection molding machines
(250 to 3,500 kN) are tie-bar-less hybrid
injection molding machines with hydraulic clamping and electric
and electric injection unit.

Due to the relocation of the tanks to the outside
the installation area of the predecessor system was
the interior for the installation of the new pump and
pump and control technology.

On the roof of the building: The chiller, which uses R290 (propane)
refrigeration machine takes over the cooling
cooling when the free cooling system (rear) is no longer
is no longer sufficient at higher outside temperatures.

The computer tomograph is supplied with water cooled to 18 to 20 degrees Celsius by an additional cold water unit.

»Consultation, installation, and commissioning were all top-notch. The overall package from technotrans is perfect.«