The iceberg model often used in business administration illustrates very well that it is not only the procurement costs that make up the total price of a machine or device, but that running and hidden costs must also be included in the considerations. Over the life cycle of a production plant, operating costs generally add up to ten to fifteen times its acquisition costs.
Considering Capex and Opex Together
When talking about the total cost of ownership (TCO), many people fail to realize that it is about more than "just" the acquisition costs (capex, capital expenditure). The ongoing operating costs (opex, operational expenditure) are just as important. They represent the essential part of the iceberg under water, so to speak, in order to be able to comprehensively map the total expenditure for an investment, in this case a temperature control unit, over its entire service life.
HB‑Therm units are demonstrably long-term investments - with a service life of at least ten years, depending on how the units are used. This is also shown by the usage statistics of numerous customers. Many companies are still using Series 3 or 4 temperature control units with over 100,000 operating hours, which corresponds to over eleven years of uninterrupted operation. The current Series 6 units (Fig. 1) offer the operator valuable support, similar to their predecessor models – albeit much more comprehensive. With operation-dependent displays for upcoming maintenance or preventive warnings, they effectively help to identify and avoid damage risks at an early stage.
If the entire life cycle of the temperature control units is considered, the economic and ecological effects are different than if only the purchase price is taken into account. The weighting of the individual items for a consideration of the TCO shifts massively in some cases, as variables such as sustainability or the impact of the new purchase on the CO2‑footprint of products and production are then also included in the consideration. A unique advantage of Thermo-6 units in this context is the lifetime warranty on the heater and flow meter. This not only saves on spare parts, but also avoids unplanned process interruptions due to repairs and thus production downtimes lasting several hours.
Influence of Extensive Basic Equipment on the TCO
If we look at the purchase of temperature control units from a more detailed perspective, energy efficiency, control and technical features also come into play in addition to basic equipment and functions, sustainability and CO2‑footprint. While many suppliers entice customers with low entry-level prices for their basic products, which are only minimally equipped, the ratio of basic equipment to additional features is very positive for customers with Thermo‑6 temperature control units: in the technical data, the standard features cover an entire printed page, while customers can only order five additional features. These are the leak stop mode, a connection for alarm and external control, a connection for external sensors, monitoring of the return filter and mold emptying with compressed air.
From the manufacturer's point of view, the extensive basic equipment of the Thermo‑6 units makes sense: the features are implemented in software or hardware and are essential for safe, reliable and sustainable operation of the temperature control units. In addition, thanks to the corporate strategy, the lean variety of types enables a solution for many different tasks.
Lower Operating Costs with Speed-Controlled Pump
The software and hardware features included as standard have a beneficial effect in the medium and long term. With the "Energy‑Control" control assistant, an optimum operating point can be achieved in just a few steps. The result is up to 90% lower power consumption. The assistant brings the variables of speed, flow rate, temperature difference and energy saving into an effect-oriented relationship. Identifying the optimum operating point is made easier by a simple visual display that shows the current pump speed, the difference between main and return in Kelvin and the savings per year in euros.
HB‑Therm uses speed-controlled pumps as standard on all Thermo‑6 units, which lead to an immediate reduction in costs thanks to their energy-saving operation. This allows the pump characteristic curve to be adapted to the application so that the desired flow rate is achieved with minimum energy consumption. However, it is usually not clear from the outset which temperature control is the right one for a process. The HB‑Therm unit control system therefore offers the option of selecting a suitable preset eco mode (Fig. 2)
- with automatic monitoring level,
- with constant pump speed,
- with constant flow rate.
- with constant temperature difference,
in order to optimize the energy use of the units in every case.
Energy-Efficient "Direct‑Drive" Pumps
In addition, direct-drive pumps in the Series 6 for applications up to 100 °C reduce energy consumption. Thanks to their special design, eddy current losses are avoided and energy consumption is reduced by a further 20 % compared to the already efficient "normal" speed-controlled pumps.
The "Direct-Drive" pumps are available in two versions: the type 4T for normal applications with flow rates of up to 65 L/min and the 6P with up to 140 L/min for more powerful applications. The pumps impress with their compact design, which delivers three times the performance of conventional pumps of this size.
For reasons of complexity, the development of new, more efficient pump technology could have been dispensed with, which would also have been more attractive in terms of procurement, i.e. purchasing and logistics. However, the aim of using these pump types is to achieve the best possible performance for each application and each unit type through appropriate developments. Such optimizations have a far-reaching effect due to economies of scale in large production halls or on a global level – a central component of HB‑Therm's basic idea of achieving sustainable improvements even with the smallest contributions per unit.
Energy Efficiency through Correct Unit Design
Energy efficiency was the top priority in the development of the Thermo‑6 units. As a consistent further development of the tried-and-tested Thermo‑5 units, the unit concept has been comprehensively improved here, including the entire hydraulic concept, which has also been impressive in terms of energy consumption since Series 4 thanks to its tankless design with a correspondingly lower circulation volume of 1.4l (Fig. 3). Both the connecting elements and the specially developed modules, such as the heater or the proportional module for bypass control, have been further optimized to ensure that the medium flows as harmoniously as possible. The result is lower pressure drops, which equates to a lower energy requirement for the pump with the same output.
The reduced load also reduces wear, which in turn has a positive effect on the service life – two aspects for positive TCO and ROI. Expressed in figures, this means that around 27 % less energy is consumed when using a Thermo‑6 temperature control unit compared to a Thermo‑5 – simply by designing the unit accordingly. If you also take into account the 20 % saving of the "Direct‑Drive" technology, this always means an energy saving of 42 % for the same application. This is despite the similar design of the Thermo‑5 with tankless hydraulics and modular construction.
Immediate Cost Savings of EUR 559 per Year
The "Energy Consumption Comparison" (ECC) program from HB‑Therm can be used to compare generations. It compares two HB‑Therm units on the basis of real practical values and shows the savings potential of new technologies depending on the application. In a sample calculation, identical speed-controlled Series 5 and 6 units are compared. Despite the same operating mode, savings of EUR 559 per year are possible when switching from the older to the newer series (Table 1).
If you consider this over a service life of 15 years, for example, this equates to EUR 8385 – which means that the Thermo‑6 units not only pay for themselves over their service life, but also generate a profit thanks to their highly efficient operation and have a positive impact on the ROI figure.
Vision of the Most Energy-Efficient Temperature Control Unit
The energy efficiency of the units also influences sustainability and the CO2‑footprint. In the case of HB‑Therm, a second factor plays a role here – in addition to energy-efficient operation at the customer's premises: the energy-optimized, sustainable production of the units at the St. Gallen/Switzerland site. For HB‑Therm, the commitment to sustainability is a central aspect of its corporate identity, which is reflected in the continuous optimization of its own CO2‑footprint. The high degree of lean in-house production, the steadily increasing level of automation, the consistent tracking of supply chains and engineering under one roof are the key to HB‑Therm's pioneering role, also with regard to the development of what it considers to be the most energy-efficient temperature control unit currently on the market, Thermo‑6.
Consideration of "Gray Energy" in the Total Cost Analysis
How is the so-called "gray energy" included in the total cost analysis (TCO)? Ultimately, the focus is on the entire product life cycle, both from HB‑Therm's and the customer's point of view: from development to production and use through to recycling. HB‑Therm thinks about this as early as the development stage: What about the cost of recycling at the end of the product's life? Or do you give the units a "second chance" and thus avoid complete disposal? While many companies today are planning an obsolescence strategy with a fixed end of life cycle, HB‑Therm not only tries to keep operating costs low over the lifetime of the units, but also to extend the service life through a long-term supply of spare parts as far as the supply chains and production technologies allow.
The Swiss temperature control experts already have the life cycle and end of life in mind when developing and building their units. Thanks to the modular design, it is possible to replace individual modules at any time without having to dispose of an entire unit. This means that modern technologies can also be retrofitted to the first versions of the respective series, giving the unit not only a longer service life but also state-of-the-art technology. If the units really have reached the end of their service life, HB‑Therm or the relevant national distributor will take them back – if transportation is worthwhile – and send them for professional, sustainable recycling.
Quality Pays for Sustainability
The quality of the Thermo‑6 temperature control units is also an important sustainability factor. The unit components are made of durable and high-quality materials such as stainless steel, brass or fiber-reinforced high-performance plastics, which have been specially selected for demanding applications. This has a positive impact on the overall efficiency and sustainability of the units thanks to their durability.
The simple, intuitive operation and handling of the units also contributes to the quality aspect. Various sensors such as temperature sensors, pressure sensors and the corresponding software for evaluation and identification, which are installed in the units, enable highly automated monitoring of important functions relating to productivity and production reliability – which minimizes sources of error and therefore rejects. "Autotuning" functions allow the units to continuously optimize themselves. In addition to comprehensive sensor monitoring, the Series 6 units are also safe thanks to hose breakage detection.
Digitalization Makes Temperature Control Smart
When it comes to the digitalization of temperature control, the Series 6 is one of the pioneers in the industry. Although many are talking about the digital twin, HB‑Therm already has it (Fig. 4). Process data recording, unit history, problem solving "on the spot", maintenance orders and spare parts supply through unit-specific documents such as certificates, calibration data, spare parts lists, operating and installation instructions: Series 6 units offer all customers who so desire unrestricted and data-secure access to the digital world Even with all relevant process data on any mobile device (Fig. 5). The digital options have been expanded again for Fakuma 2024. In particular, many new digital features can now be used free of charge via the e‑cockpit app, even without Gate‑6. However, the Gate‑6 interface server still has its place for using remote functions (Fig. 6).
Conclusion: It Is the Big Picture that Counts!
Buyers of temperature control units who base their calculations solely on the purchase price are being very short-sighted. On the other hand, those who take quality, energy efficiency, durability and sustainability into account when making a purchase will make a well-founded investment decision when considering the total costs. The situation is similar with ROI, an important key figure when it comes to investments. This is because if all important purchase criteria that say something about the future viability of the investment are included in the calculation, the amortization period for a long-lasting unit will also be much more favorable.
Test without obligation
Interested parties in over 60 countries can request a free loan unit from the company's sales partners to test the advantages of the technology in real-life use.
