Case Study

Case Study

The largest LNG-powered cogeneration unit in southern Poland – Schumacher Packaging Myszków

The largest LNG-powered cogeneration unit in southern Poland is now operating at Schumacher Packaging in Myszków. Thanks to an investment of 21.8 million PLN, the facility has achieved nearly 80% energy independence, producing almost 9 MW of electricity and significant amounts of heat. The project, implemented by DB Energy, demonstrates how an energy audit can serve as a starting point for a comprehensive energy transformation of a factory – from modernization of existing heat sources, through energy recovery, to the implementation of advanced cogeneration.

Higher production and lower emissions – a chemical industry client on the path to net zero

At a chemical plant in southern China, we developed a 4-month strategy to reduce emissions by 70%, enabling increased production while lowering energy consumption and laying the groundwork for achieving net zero by 2035.

Zero-emission in practice – emission reduction in pharmaceutical chemistry

Zero-emission in the chemical industry is not theory but concrete action. For a client in the pharmaceutical sector, we prepared a CO₂ reduction roadmap and implemented an incinerator modernization with heat recovery. The result? 12 GWh of thermal energy saved, a reduction of 2,172 tCO₂, and a quick payback period.

From energy audit to 40% CO₂ emission reduction – modernization at Soufflet Polska

DB Energy implemented an investment at Soufflet Brewery: heat recovery, cogeneration, and a new cooling source. Result: 40% reduction in CO₂ emissions, 42 GWh energy savings, and an ESCO-model investment worth 29 million PLN.

Modernization of lighting installation in the wood processing industry

DB Energy carried out a project to modernize the lighting installation at a wood industry facility. The implementation of modern LED fixtures and a DALI control system significantly reduced electricity consumption, generating measurable financial and environmental savings.

Heat recovery from the production process

In the plant producing OSB boards, DB Energy implemented a heat recovery system from the formalin cooling process. The waste energy was used for the belt pre-dryer, reducing energy consumption by over 106,000 MWh, generating savings of around PLN 9.6 million, and cutting CO₂ emissions by 40,000 tons. The simple payback period is 4 years.

Modernization of the CHP plant at Schumacher Packaging – annual savings of 20 million PLN

DB Energy carried out a comprehensive modernization of the CHP plant at the Schumacher Packaging facility in Myszków. The 43.4 million PLN investment enabled a 20% increase in boiler efficiency, annual savings of 20 million PLN, and a reduction of CO₂ emissions by 24,000 tons.

Modernization of Simoldes Plasticos plant – comprehensive improvement of energy efficiency

At the Simoldes Plasticos plant, DB Energy carried out a comprehensive modernization program: from an audit, through LED lighting, compressed air system and free cooling, to heat recovery and drive control. The result was a 25% reduction in energy consumption with financing under the ESCO model.

Optimization of pressure in the cooling system

In the food plant, we optimized the cooling system, reducing energy consumption by 800 MWh/year and CO₂ emissions by 640 tons. The modernization increased compressor efficiency and generated savings of up to 600,000 PLN annually.

Freecooling in a production plant

Freecooling in cooling systems is a simple modernization with high potential. In a production plant, it reduced energy consumption by 1 GWh/year, cut CO₂ emissions by 800 tons, and generated PLN 300,000 in savings.

Application of a gas turbine for electricity generation

In metallurgical processes, large amounts of blast furnace gas energy are lost during pressure reduction. DB Energy designed a solution based on gas turbines, which enabled the recovery of 211 GWh of energy annually and reduced CO₂ emissions by more than 170,000 tons

Steam turbine installation for electricity generation

Instead of wasting energy on steam parameter reduction in a cooling station, the chemical plant used it to produce its own electricity. The installation of a steam turbine with a synchronous generator made it possible to utilize over 87 GWh annually and significantly reduce electricity purchase costs from the grid.

Installation of a fan control system

The installation of inverters and a supervisory fan control system in commercial and warehouse buildings enabled a reduction in energy consumption of 1.49 GWh per year. The modernization lowered operating costs and improved user comfort.

Replacement of air compressors and implementation of a supervisory control system

Replacing old air compressors and implementing a supervisory control system in a metallurgical plant reduced electricity consumption by approx. 800 MWh per year. The modernization improved installation efficiency and lowered compressed air production costs.

Modernization of fan drives – reduction of energy consumption by 9,868 MWh

Modernization of fan drives in an industrial facility brought savings of nearly 10,000 MWh per year. The use of frequency converters and precise speed control allowed for reduced energy costs and CO<sub>2</sub> emissions, eliminating losses associated with flow throttling.

Modernization of lighting in the technological process area

The modernization of lighting in a construction industry plant demonstrated that even without significant investment outlays, it is possible to achieve substantial results. Through simple measures such as the use of natural light, installation of motion sensors, or repositioning of fixtures, the company reduced energy consumption by more than 103 MWh annually and gained an additional benefit in the form of White Certificates.

Installation of a compressed air recovery system from a process machine

The implementation of a compressed air recovery system in a plastics manufacturing plant reduced energy losses and lowered costs by more than PLN 230,000 per year. The payback period of the investment was less than one and a half years.

Modernization of the dedusting system – energy savings and improved working conditions

Thanks to the modernization of the dedusting system and the use of automation, we reduced energy consumption by 3.38 GWh and cut costs by more than PLN 1 million annually. At the same time, we improved working conditions in the wood processing plant.

Heat recovery from heating furnace carts

Heating furnace carts with waste heat from tunnel furnace flue gases reduced gas consumption and saved 4.09 GWh of energy annually.

Insulation of dyeing machines

Insulation of dyeing machines reduced thermal energy consumption by over 50%, resulting in 20.93 MWh saved and 2.3 million PLN in avoided costs

Replacement of transformers

Replacing 19 transformers with modern low-loss units achieved savings of 747 MWh of energy and 244,000 PLN per year.

Improvement of heating network insulation

Modernization of the heating network insulation reduced heat losses in pipelines and heat nodes, resulting in savings of 3.1 GWh of energy and 260,100 PLN annually.

Replacement of air handling units with supply-and-exhaust systems

Modernizing air handling units to supply-and-exhaust systems with heat recovery reduced energy consumption by 2.55 GWh per year and improved thermal comfort in production halls.

Cogeneration – combined production of electricity and heat

The implementation of a cogeneration system enabled the simultaneous production of electricity and heat with flexible operation of the units. Thanks to this, DB Energy achieved annual savings of PLN 2.89 million and improved the facility’s energy efficiency.

Modernization of the blower on the evaporators in the metallurgical plant

The modernization of the process blower enabled the reduction of pressure losses and energy consumption in the metallurgical plant. Thanks to the new blower station and improved air regulation, the client achieved annual energy savings of 7.82 GWh.

Automatic control of the excess air ratio in steam boilers

Optimizing the excess air ratio in steam boilers significantly reduces chimney losses and coal consumption. Thanks to automatic control, DB Energy achieved annual savings of 13.09 MWh of energy and improved boiler house efficiency in a food processing plant.

Modernization of the burner air system in a cement plant

In cement plants, the proper temperature of primary air in burners determines combustion efficiency. Thanks to the modernization of the air supply system and the use of hot waste air, DB Energy reduced energy consumption by 139.7 GWh annually, achieving savings of PLN 3.23 million.

Modernization of steam heat exchangers

Steam heat exchangers are a key source of heat in industrial processes. Thanks to the modernization of 17 units, DB Energy’s client reduced energy losses, improved heat exchange efficiency, and achieved annual savings of over PLN 10 million, with a payback period of less than 2 years.

Removal of leaks in the compressed air system

Compressed air leaks are one of the most common sources of energy loss in industry. Thanks to an audit and repair work, DB Energy helped a client in the construction sector reduce energy consumption by 2.21 GWh per year, achieving a quick payback.

Audit and modernization of the lighting installation in a steel mill

Modernization of the lighting installation in a steel mill is an example of an investment that combines cost and emission reduction with obtaining white certificates. Thanks to the audit and replacement of fixtures with LEDs, the client reduced energy consumption by up to 60%.

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