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Insights

 The Hoval Group magazine for customers and employees Winter 2011/12

Good by tradition!

The new product design shines in a self-confident red


I nsight s 2

Preface

Dear Reader We’re going red! Rarely have prognoses about

We have clear goals, motivated employees and

the world economy been as uncertain as they

stand out above the competition. This is exactly

are today. Any optimism is being damped by

what we intend to underscore with our new

national debts that have continued to grow

design. A design that goes its own ways.

unchecked in many countries. The battle

A design that highlights our high technical

against climate change has been degraded to a

standards but also our courage to take the

beauty contest in many countries, despite its

colour back to our roots. The first, legendary

long-term existential consequences.

Hoval boilers were red.

In this environment, it is good to know what

Enjoy this reading adventure!

characteristics have made our company strong. And we are fully aware of them. They are traits like our passion for technology and our ­emphasis on family values. Our very awareness of these values is another aspect of our ­sustainability. This approach has certainly contributed to the positive development of our business, continuous over the last ten years.

Peter Gerner, Executive Board Hoval Group/CEO Heating Technology

Even if our growth has slowed briefly in the current t­urbulent environment compared to recent years, we remain unswayed in setting forth our success story.

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Content

Insights Winter 2011 / 12

4

10

12

20

13

In focus

In detail

04

Good by tradition. Design change after 30 years.

18

EcoLine: The system solution for supermarkets. Intelligent & efficient.

In operation

20

07

Everything from a single source. Complete ­solutions delivered ready to operate.

Twelve years of wood pellet boilers from Hoval. The first system is generating heat in the product developer’s own home.

10

The Nile island – a place to relax.

In retrospect

23

The Hoval magazine in years gone by: A look back at the “Hoval Newsletter” of December 1955.

In the market

12

Disaster aid for Japan. A little joy for children in need.

13

Hoval in Asia. New partner with a future.

Winter 2011 / 2012


I nsight s 4

In focus

The new red Hoval boilers being greeted by Hoval employees, customers, partners and media representatives with fireworks.

The new look of Hoval products is red! Why is Hoval introducing a new design after 30 years? Easy: Innovative technology demands an exceptional look. The new boilers are being introduced on the international Hoval stage in a series of spectacular events. It was a long road from the first draught to the first launchable product. But then the moment of the premiere had come: 12 April, Vaduz (FL), 230 guests, 3 stars. There they stood in the limelight and all eyes were on the bright red ® forms of the UltraGas (125), ® ® UltraOil  (16) and Thermalia  (10) units. ­Thundering applause for the first three models that presented their new look to our sales force. The international tour was kicked off! 06 May, Trafo in Baden (CH), 370 guests. The Hoval products are still veiled on the stage. But the

s­ uspense is mounting. “Then the ­f ireworks go off, the veils fall, and we see the large Hoval logo shining bright red on the new products. The light slowly falls onto the boilers and shows them in their fully beauty.” This is how Monika Storkan of Hoval Switzerland experienced the brand launch day to which all employees throughout the country were invited. The musical finale was p ­ resented by a chorus that ­administrative employees of Hoval ­Switzerland had assembled ­spontaneously. It was met with a ­standing ovation for the “Hoval anthem”, composed and expertly performed just for this occasion.

07 May, scalaria in St. Wolfgang (AT), 300 guests. “Spectacular show for a new design” was the headline in the “IKZ-Haustechnik” magazine when it reported about the Hoval partner event at the Wolfgangsee. Artists from earlier productions of the “Cirque du Soleil” and winners of the “Golden Clown Circusfestival Monte Carlo” accompanied the unveiling of the newly designed Hoval products. The artists portrayed the elements of fire, water, air and earth, all of which are energy sources in the Hoval product world. But the true heroes of the ® evening were red: Thermalia (5-17),

Insights


Spectacular show at the presentation in St. Wolfgang (AT): Artists portrayed the elements of fire, water, air and earth – the energy sources of Hoval products.

BioLyt (100-160), AgroLyt ® (25), ® ­UltraGas (1000), TransTherm transfer ® stations and HomeVent RS-500 were closely inspected and admired by the guests. 18 May 2011, Grindelwald (CH), 37 nations. For the first time, the “Hoval World Sales Meeting” brought together all Hoval partners from the climate technology and heating technology business divisions for the New Markets. In line with the brand positioning slogan, “Technologically superior heating and indoor climate control ­solutions from the Alps”, the convention

took place at an altitude of 1,034 m. The lively exchange of technical expertise and future sales and marketing strategies and the presentation of the new ® design using the UltraGas (125) were the main themes of the 3-day meeting. The family-oriented segment, of course, was not forgotten and brought some of the visitors into contact with snow and ice cold temperatures for the first time. Protected in warm clothing, the group ascended the Jungfraujoch to an altitude of almost 3,500 m, went on a glacier hike and experienced first hand that “the Hoval team can be relied on”.

“After over 30 years in redorange, we are returning to our roots. Beginning in autumn, our heat ge-nerators will once again be red.” Markus Telian, Director of Research & Development.

More voices:

“The new design is of very high quality. It is an excellent ­expression of the sophisticated technology and quality of our products.” Peter Gerner, CEO Heating Technology

New boiler design ■ The control panel is located under the prominently positioned Hoval logo ■ The characteristic, slanted Hoval front has been retained as a “brand feature” and has been ergonomically optimised for convenient operation ■ The logo and control panel are illuminated ■ A groove between the front and the body subdivides the device visually and gives it a smaller appearance ■ The inside appearance is “orderly” and components are easy to access

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“The Hoval logo now has more ■ The two-colour design (RAL 3000 at the front, RAL 3011 at the rear) ­visually reduces the size of the unit

space and more brilliance – in the true sense of the word.” “IKZ-Haustechnik” magazine.

■ The anthracite-coloured base is set back to give the device a “light” appearance and creates foot space for the user

“A heat generator’s design is an

■ Pleats in the front lend the large red surface a dynamic structure

to develop visually appealing

■ The front hood attachment has been modified and the hood can be removed by one person

important feature. It was a major challenge for us equipment. After all, an attractive design invariably influences the decision to buy.” Jürg Nufer, Managing Director of Hoval Switzerland.


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In operation focus Italy

Heating and saving at an astonishing level The call of the J. F. Kennedy technical school is clear and concise: “Come and discover where the future is being born.” The school in Pordenone in ­northern Italy trains technicians and planners of the region. Now in its 50th year of existence, it is demonstrating how to save energy. This, too, is part of the future. The change from oil to gas was already advantageous for the forward-looking institute. The fact that it then also ® decided for three Hoval UltraGas (2000D) condensing boilers led to an even greater reduction in CO2 emissions: The annual output of 1430 tonnes is now lower by 300 tonnes. This is a reduction of almost one quarter. ­Cascaded with the gas boilers is a wood chip heater in the M. Grigoletti science high school, 500 m away. ­Consequently, the total CO2 output has been reduced by 892 tonnes per year. “These CO2 reductions appear incredible at first glance, but they are true,” says Günther Köb, Head of Development, Oil and Gas at Hoval. Just after he joined Hoval in 1993, he drew the ® first prototype for the UltraGas ­condensing boiler. In February 1994, it was taken into service on a test bench at Hoval in Vaduz – and promptly ­delivered the desired results. After

these cautious beginnings, the ® ­UltraGas embarked on a successful career that has lasted to this day.

“The amount of energy saved by the system in Pordenone will pay for the system in five years.” Günther Köb, Head of Development, Oil and Gas

Nevertheless: “The extent to which the ® UltraGas condensing boiler creates savings is still not clear to everyone,” says Günther Köb. The fuel is optimally utilised with a coefficient of performance that is far above average. The amount of energy saved by the system in Pordenone will pay for the system in five years. In this computation, Günther Köb also includes the investments made in the building for setting up the new central heating system and the

costs for the installation and exhaust ducts. The recurrent cost savings far exceed 120,000 euros per year. With a projected service life of twenty-five years and an amortisation period of five years, potential savings amount to far more than 2.4 million euros (at constant energy prices). Exceptional performance is also achieved by the modulation capability ® of the UltraGas condensing boiler. The shared heating system of the J. F. Kennedy technical school and the M. Grigoletti high school can vary its output according to need from 200 kW to 6000 kW. Its modulation ratio of 1:30 should receive widespread attention throughout the sector. At the J. F. Kennedy technical school – and at Hoval – the future is indeed being born. That’s something to marvel at, with both relief and optimism.

The six Hoval UltraGas ® (1000D) units in the basement of the Kennedy school.

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Liechtenstein

Heating with pellets – a good thing. The community of Triesen, right next to Vaduz, decided for the obvious and for the practical – protection of the environment and a pellet heating system. The know-how of Hoval, its neighbour, brought with it other singular advantages. “The people at Hoval don’t just talk about environmental protection. They actually do something about it.” Walking over the church square, Dominik Oehri comments that Hoval doesn’t simply follow a trend, it takes the issue seriously. Behind him is the rectory, to his right are two kindergartens and in front of him the church portal. All four buildings are now heated by one wood pellet system. Dominik Oehri planned it and Ospelt Haustechnik installed it. ENB Energieplanungs-Anstalt, Dominik Oehri’s engineering office in Schaan, Liechtenstein, specialises in building technology and the use of alternative energies.

“The people at Hoval don’t just talk about environmental protection. They actually do something about it.” Dominik Oehri, ENB Engineering Office, Schaan

Mr. Oehri, why pellets? “To replace the previous three auto­ nomous oil heating systems, we con­ sidered a wood chip heating system, a heat pump and a pellet system. The choice fell on the pellet solution because it is simply the most practical for the Triesen church community. The driveway to the central heating system is narrow and is difficult for lorries to manoeuvre.

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Wood chips would have to be delivered every two weeks. In addition, the rectory would have had to be expanded to store the chips. Chips require considerably more space relative to their calorific value. Does the current storage area provide enough space for the pellets? “Yes, a room that previously held an oil tank is now used for pellets. The other oil tank rooms are being used as additional basement rooms. The delivery lorry only needs to come twice a year. It brings 15 tonnes at once, and the pellets are simply blown into the basement with suitable equipment. The pellets are removed with two mole vacuum systems. Thanks to this special intake equipment, we did not need to modify the old oil tank room significantly to store pellets.” On a very cold winter day, a boiler output of 110 kW would be necessary. But the two Hoval BioLyt (50) for which you decided only output 100 kW… “Experience has shown that the church community almost never fully heats all of the buildings at the same time, even in the depth of winter. For this reason, we decided – together with Hoval specialists – to install a system that is slightly undersized.” When heat requirements are low, the boilers operate alternately. Why? “In this way, the church can preserve the life of both boilers. Even when they are cascaded during high demand, the lead boiler still alternates between the two. As a result, the operating hours

accrue at the same rate for both units, and the service technician encounters both in a similar state. The maintenance and cleaning intervals remain the same for both units. It’s simply a question of savings. In addition, the double-boiler system increases reliability.” For Dominik Oehri, this project has been a good thing all around. Interview: Ursula Trunz

BioLyt – space saving and functional. The common opinion that pellet heating systems require a lot of space is simply not true. A Hoval BioLyt has only a slightly larger ­footprint than an oil heating system. In the space-saving, functional design, the burner is positioned at the front and the exhaust connections at the rear – making it unnecessary to access the unit from all sides. Also unique is the vacuum conveying system, which is compatible with all pellet storage systems. Space-­ savings and flexibility in design are major advantages, especially when replacing existing heating systems.

Dominik Oehri, planner.


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In operation focus France

Everything from a single source – and in a container. What if there is no space inside a building for a central heating system? Easy, says Hoval –

and “packs” everything into a single container. This high quality solution was right for the automaker Peugeot. The central heating system in a container will satisfy a range of situations: It is compact – and can be sized for outputs from 100 kW to 10 MW. The container has flexible dimensions – and can be set up as the customer requires. Two such containers holding one 1800 kW CompactGas boiler each are located next to the Peugeot production plant in Mulhouse. The containers arrived by air. A pneumatic crane lifted them from the lorry onto the prepared foundation where they were bolted together firmly. The entire installation procedure only took around two days. A thermally insulated Hoval container can only be installed in one or two days because everything inside it has already been prepared and installed. Even the chimney is already there. “All we need from the outside is power, gas or oil, and water,” says Franck Weber of Hoval France in Strasbourg. He worked

on the development of this solution together with Hoval in Vaduz. “The external supply is handled by the ­customer. We take care of everything else.” In saying this, Franck Weber is also referring to the planning. The scheme for the hydraulic and electrical systems also comes from Hoval.

“The external supply is handled by the customer. We take care of everything else.” Franck Weber, Hoval France

“The customer gets everything from a single source,” summarises Business Developer Lebi Gubser at the headquarters in Vaduz. “This makes things much easier for the customer. Of course he can choose how to set up the container. He can equip it with a steam boiler or with a climate control system

– whatever he needs.” In addition, the container is available in a fire-resistant version that can withstand a fire for two hours.

The container solution will definitely become an important business segment for Hoval in the future, predicts Lebi Gubser. “The automaker Peugeot is planning to use containers in other ­locations as well. Hoval Spain has also reported that containers have been ordered, planned and installed.” At Peugeot in Mulhouse, incidentally, the heated boiler water is used for the paint baths to keep the paint temperature constant. The system has a total energy efficiency of more than ­95  percent.

The first part of the container solution with a 1800 kW CompactGas boiler in front of the Peugeot building in Mulhouse.

Insights


Poland

Rolls-Royce and Hoval are doing something for the climate. The good indoor climate in the new Rolls-Royce plant in Gdynia

is produced by the RoofVent ® supply and extract air handling unit from Hoval. Rolls-Royce travels the oceans: Its network of “Marine Service Centres” spans 35 countries. Around thirty RollsRoyce employees in Gdynia, Poland, maintain and service ship diesel engines and gas turbines, handle marketing and sales throughout the Baltic region and organise spare parts deliveries. Another fifty colleagues work as mobile service engineers. The organisation was formed only a few months ago – as the building for the “Marine Service Centre” was being erected. The shipping port in which it lies is one of the busiest and most important on the Baltic Sea. Ensuring that the working climate in the Rolls-Royce “Marine Service Centre” in Gdynia was comfortable from the outset was Hoval’s job – or to be more precise: ® that of the RoofVent roof ventilation unit. The ventilation, heating and cooling units installed on the roof of the “Marine Service Centre” supply the

“Marine Service Centre” of Rolls-Royce in Gdynia

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i­nterior with fresh air and extract used air. The integrated plate heat exchangers recover the heat from the air being extracted. This technology saves energy and keeps operating costs low. With a good indoor climate, the corporate climate will surely get off to a good start. Responsible, informed and solution-oriented cooperation across national borders is important to Hoval as well. The “Hoval family”, although scattered throughout the world, is unified through its shared values. On the basis of this mutual understanding, Hoval colleagues in Poland and Germany worked together to support Rolls-Royce in its “landfall” in Poland. The Hoval engineers in Germany were at the helm of the project when it came to planning the entire ventilation system with heat recovery, while their Polish colleagues handled the implementation.

RoofVent ® RoofVent ® are roof ventilation units for supplying fresh air and removing extract air. They heat and cool the supply air using integrated heat exchangers, saving energy through heat recovery or mixed air operation. They can even be equipped with a decentralised heat or cold generation unit.


I nsight s 10

In operation focus

The island emerges from the Nile like a butterfly – fun and relaxation are guaranteed.

A detailed plan of the complex facility

Egypt

Tailored solution

An E-mail from Egypt triggered immediate action at Hoval in Vaduz. Just a few months later, the hot water and steam system for the extension of a hotel in Luxor was in operation. The first guests could move into the facility’s new bungalows and villas.

The technical manager of the Maritim Jolie Ville Kings Island hotel in Luxor knew exactly what he wanted. After all, he was already familiar with the proven Hoval systems in the three hotels in Sharm El Sheikh, which also belong to the hotel chain. He wanted a tailored solution with high reliability and superb quality, but also with good cost ­efficiency. Daniel Heiss, Export Area Manager for the Middle East, Turkey and North Africa, remembers the day the E-mail arrived from Luxor, on 24 February 2010, like it was yesterday: “It even specified the exact type designation.” He immediately got to work in far-away Vaduz, travelled to Luxor together with Export Director Harald Verling for a first-hand look and a short meeting, planned the required systems – and held the order in his hands on April 15. “The time schedule was indeed very tight: the 400 additional rooms had to

be ready by Christmas since guests had already been booked.” In every phase of the project, Daniel Heiss was in close contact with the Egyptian Engineering & Industrial Office for Energy Technology (EEIOET), which has been representing Hoval in Egypt since 2004. Youssef Nosseir, who together with his wife Elvira Guindi owns EEIOET, worked tirelessly to clarify the details. In June, two steam boilers, two hot water boilers and six Modul-plus for hot water preparation were delivered to Egypt directly from the plant. Youssef Nosseir and his team could begin with the installation. “Together with the customer, we decided for a split system that achieves a high coefficient of performance with precisely sized steam and hot water boilers,” says Daniel Heiss. “The two steam boilers produce only the amount of steam that the laundry actually

needs. Added to this are six high performance Modul-plus calorifiers, two for each of the three defined zones. The Modul-plus units are supplied by the two hot water boilers.” By separating steam and hot water, the system becomes more complex but considerably more efficient to run. “This has an impact on the operating costs.” Daniel Heiss describes further important points relating to the hot water modules: Modul-plus offers a high output while occupying only little space. In addition, its special design prevents contamination with legionella bacteria. Since Christmas 2010, the 10 new ­bungalows and 36 new villas have been enjoying a reliable hot water supply. The Maritim Jolie Ville Hotel on Kings Island erected them in addition to the 21 existing bungalows. Guests can now peacefully enjoy the sunset in all its glory on the banks of the Nile.

Insights


Germany

Upgrading a decentralised indoor climate system

New units save more than 50 percent of operating costs. Indoor climate systems from the seventies and eighties should be upgraded now, at the very latest. Those who were foresighted at the time and selected RoofVent ® LHW-S-85 have many

The standardised roof frame makes the exchange between old and new an easy task. When well prepared, the mechanical installation by helicopter takes no more than three or four minutes.

advantages today, and replacement of each unit takes only a few minutes. It was on a Friday the 13th of all days that the critical phase began: The new indoor climate units were delivered to the car park of the “Gummiwerk Kraiburg” in Waldkraiburg, Bavaria. The old devices on the roof had already been prepared electrically and mechanically for rapid disassembly. The electrical lines and the heating ducts had been renewed in the preceding weeks. Everything went fast the next morning: The ordered helicopter replaced the old ® RoofVent units with the new ones. A crane would not have been able to reach all devices and their locations. One m ­ arshaller on the floor and one on the roof accompanied the manoeuvre, while one team mounted each unit. The right steps were quickly learned and everything went smoothly. On average, the teams disassembled an old unit and installed a new one every ten minutes. After a little more than three hours, the job was done. The fact that Hoval has always focussed on quality and energy efficiency is once again proving to be an absolute advantage. This time, the customers who benefit are those who, in wise foresight, purchased the indoor ® climate units RoofVent LHW-S-85 in the seventies and eighties. Thanks to their high quality and their distribution across the roof, most of the units remained operational long after the usual service life of 15 to 20 years. Units that are 30 to 35 years old are not

Winter 2011 / 2012

uncommon. Failures of individual components or entire units can at first be neglected because of their distributed arrangement. Deficits are compensated by other modules. When they are ultimately replaced, the standardised roof frame makes the exchange easy. Its dimensions have stayed the same over the years. In addition, customers who ® decided for RoofVent early on have benefitted from significant energy savings since then. The integrated, high performance plate heat exchanger transfers the heat from the extract air back to the supply air, reducing energy requirements. With its distributed rooftop climate ® system, RoofVent , Hoval offers a modular, duct-free and therefore lean solution that still challenges conventional central climate systems and their space-hogging, separate air duct networks. In addition, each individual ventilation unit can be controlled separately using a central control – yet another way to save energy. Hoval development of the RoofVent technology for handling supply and extract air, primarily for large spaces, is an ongoing process. The newly ® launched RoofVent twin heat, twin cool and twin pump product range more than meets the needs for heat recovery, a demand that has grown rapidly in recent years. The old, energy-gobbling central climate systems are clearly a thing of the past. ®

Advantages ■ Reduces primary energy ­consumption and operating costs by approx. 50 percent ■ Reaches the German EnEV 2009 comparative value ■ Improves ventilation efficiency through continuously adjustable vortex air distributors ■ Improves air hygiene through F7 filters ■ Achieves highly efficient heat recovery through double plate heat exchanger ■ Improves the cooling and night cooling function


I nsight s 12

In focus On the market Japan. A little joy after the disasters. i­mmediately. The engineers set up two tents, placed a plastic pool in one of them, and laid hoses and cables. They brought in a Hoval oil boiler to prepare hot water and a generator to cope with power failures and dropouts. The bathing station was open day and night and was so much appreciated that even the media reported on it. With warm water, Hoval creates a little joy for the people affected by the tsunami

Compassion for the Japanese people after the earthquake and the tsunami led to immediate action and assistance at Hoval. Natori, a city on the Pacific Ocean which, like the nearby Sendai, was hard hit by the disasters, received a provisional but well-equipped bathing station. It was a godsend – and not only for the homeless. The gas and power supply was out of service in many

areas, and hot water for hygiene had become a rare commodity. The initiative for the bathing station came from Peter Frick himself, ­President of the Board of Directors of the Hoval Group, at the Hoval headquarters in Liechtenstein. The Hoval partner on location, Hirakawa Guidom Corporation in Osaka, joined in

Normally, the Hirakawa Guidom Corporation takes care of the most modern bath houses of the country. Many of them operate with solar energy systems and condensing boilers from Hoval. Ever since the Japan Gas Association ® awarded the Hoval UltraGas condensing boiler with the Technology Prize in 2008, it is known throughout the country for its power and low level of pollutant emissions. This time, however, it was clearly the humanitarian effort that was the motivating factor.

England. Wood puts Hoval in the lead. The demand for heating systems that run on biomass is increasing – ­especially in England. There, Hoval is the only manufacturer of wood pellet boilers. That attracts prominent guests. Companies who use renewable energy sources for heating can count on government subsidies in England. Recently, the government enacted the “Renewable Heat Incentive”. “To meet the rapidly growing demand for these technologies, we have expanded our staff capacities,” reports Adrian Walker, Managing ­Director of Hoval United Kingdom.

Hoval is a traditional brand in England and attaches great importance to the training of apprentices. Numerous ­specialists in the plants in Lincoln and Newark completed their apprenticeship there. Along with the new colleagues in production and sales, they form strong teams. “Together we will continue expanding our leading position as the only producer of wood pellet boilers on the British Isles,” Adrian Walker ­continues. “When it comes to solar energy use and heat pumps, we are well-­positioned as well.”

From left to right: Manuela Dummer, Keith Hibberd, Sue Luton, Gary Fenley, Mark Newbert, Greg Kucharski, Scott Lowman, Rebecca Chapman, Stuart Hay, Anthony Crane, Karl McCartney (Member of Parliament), Adrian Walker (Managing Director), James Brown

The “Renewable Heat Incentive” and the leading position of Hoval United Kingdom in the country have attracted high calibre visitors. Gregory Barker, the Minister of State for Energy and Climate Change, and before him Karl McCartney, the local Member of ­Parliament, visited the plant in Lincoln. The biomass heating systems that Hoval United Kingdom has delivered until now – for BAE Airbus, the Royal Air Force and others – generate a total power output far exceeding 60 MW. More on the topic of the “Renewable Heat Incentive” can be found at: www.hoval-rhi.co.uk

Minister of State Greg Barker talking to Adrian Walker in front of a biomass boiler at the Hoval plant in Lincoln.

Insights


China. Joint venture opens up growth opportunities.

Hoval has founded a joint venture with Sinobaron, its partner in China of many years, to locally manufacture large, non-condensing gas boilers for the Asian market. Fabian Frick, CEO Climate Technology and New Markets explains the background. Long before other companies were even thinking about it, Hoval was active in China. Beginning in 1985, Walter Tschanz began prudently building up a presence. Proactive as he was, he first worked with independent agents. Then Hoval founded its own sales subsidiary in Beijing in 2003 under the management of Bin Song. The subsidiary’s

success led to the decision in 2007 to import and sell climate technology in addition to heating technology. It was clear to those responsible, however, that Hoval climate technology could only survive in China if it was manufactured locally. The ensuing development of production capacities turned out to be the right decision: the systems continue to be a major success. To service the entire South Asian arena, Hoval founded a representative office in Singapore in 2010. With this support base for Asia, which is steered from Beijing, Hoval can flexibly adapt to local situations. This flexibility includes strengthening the market position of heating technology and therefore – like with climate technology – manufacturing certain products locally. For this reason, Hoval

England. Customers profit from short distances. For the sake of the environment, Hoval manufactures its products as close to the customer as possible. Short ­transport distances keep CO2 emissions and costs down. Hoval United Kingdom therefore set up an assembly line for plate heat exchangers at its plant in Newark, Nottinghamshire. Until now, these heat recovery systems were produced in ­Slovakia for the English market and transported by land or sea. “Our own assembly line makes us far more flexible,” says Adrian Walker, Managing Director at Hoval United Kingdom. “We are now able to meet ambitious deadlines set by our ­customers. Saving time means saving money, for customers too.” The heat exchanger plates are cut to size in a highly ­efficient process at the Newark plant according to the ­patented Hoval design and then mounted on the basis of ­precisely calculated specifications. Hoval United Kingdom primarily supplies manufacturers of ventilation systems and adapts the plate heat exchanger performance to the specific projects in which they will be used.

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From left to right: Fabian Frick and Xiao-Dong Zhang signing the contract in Tianjin.

has now entered into a joint venture with Sinobaron, its long-standing partner. The production department manufactures large, non-condensing gas boilers that primarily cover the power ranges between 1 and 10 MW. Hoval is convinced that this joint venture will be favourable to its presence on the Asian market. The expected growth will open further opportunities for products manufactured in Europe.

Bulgaria. Now a member of the Hoval family.

.

Customers in Bulgaria can now profit directly from all Hoval services. Since the summer of 2011, Hoval advises and ­supports them with its own organisation and supplies them with systems for heating, climate control and ventilation. Hoval Bulgaria is directed by Atanas Atanasov. Technical questions and project management are handled by Kostadin Djampalski. “Our Hoval family continues to grow,” says Iliyan Pavlov, responsible for the Integrated New Markets at Hoval. “As a result, we will be able to demonstrate our expertise to new customers and inspire them for Hoval.”

From left to right: Atanas Atanasov, Branch and Sales Area Manager Kostadin Djampalski, Technical and Project Services Manager


I nsight s 14

In detail focus

Liechtenstein

From Vaduz to Siberia – and to the tropics.

Investment in the future: At its headquarters in Vaduz, Hoval has set up its own test benches for heat pumps to optimise technological development. Customers will be the first to profit. Yes, Hoval employees have a passion for technology – and they show their enthusiasm and con­ viction. “We trust in our expertise,” explains Stefan Müller. He is responsible for heat pump development. “People who choose this technology to heat their rooms and their water decide for an economical use of electrical energy. And those who choose Hoval systems obtain quality and efficiency in addition. The products we develop are well received in the market.”

Swiss Franks – and to the “quantum leap that we are making in the field of heat pumps”.

This growing technology, its previous success and Hoval knowledge and skills in this field are what ultimately gave the impetus to build the two test benches. Peter Gerner, CEO Heating Technology, points to the investment of around one million

Stefan Müller and Project Manager Christian Heller planned one test bench for air-water and one for brine-water heat pumps. The test benches they built together with Peter Engler (test bench manager) and Jörg Brand (heat pump developer)

“And those who choose Hoval systems obtain quality and efficiency.” Stefan Müller, Head of Development, Heat Pump Systems

Insights


Peter Engler, Christian Heller and Stefan ® Müller with the Thermalia twin in front of the climate chamber.

® A Belaria in the interior of the climate chamber during a test.

Roland Oehri and Beni Zeneli checking the hydraulic system.

cannot be bought. They are based on Hoval know-how – and on the experience of Michael Eschmann, who directs the Heat Pump Test Centre (WPZ) at the nearby University for Technology in Buchs (NTB).

system will be inspected for approval by the WPZ of the NTB in the near future. Heat pumps that are inspected at the WPZ can obtain the international quality seal. The test centre in Buch concentrates on power ranges up to 20 kW for air-water and up to 50 kW for brinewater systems. “Hoval heat pumps, which lie above this power spectrum, can now be tested directly at our ­headquarters in Vaduz,” Stefan Müller declares.

And now to the quantum leap. The two test benches accelerate and reinforce further development of the successful ® ® Hoval Thermalia and Belaria heat pumps. The test system will also make advances into higher power ranges ­feasible – ranges that up to now have not been reachable with heat pump test benches in Switzerland. “Our customers can anticipate that we will be raising the performance of this technology to the next stage of development.”

For the layman, the test bench for brine-water heat pumps looks like a small refinery with looping and intertwining lines, all of them of stainless steel. To test air-water heat pumps, Christian Heller set up a climate chamber that can generate subzero Siberian temperatures, at least down to minus 20 °C, and can also simulate tropical jungles with temperatures up to 43 °C and a relative humidity of 65%. “We built our system to use the exhaust heat from heat pumps to warm the climate chamber,” explains Christian Heller.

Heat pumps for every application field Hoval offers heat pumps for all ­application fields. The heat pumps feature high coefficients of ­per­formance (COP) and can be

easily combined with other heat ­generators. Ready-to-install complete systems with a compact design ­simplify installation and save space.

“... We will raise the performance of this technology to the next stage of development.” Peter Gerner, CEO Heating Technology and Executive Board Hoval Group

The heat output and coefficient of performance (COP), which expresses the ratio of heating power to consumed electrical power, are the two most important parameters. “To determine these values, we integrated technologically advanced measurement equipment in our system,” explains Christian Heller. Every temperature and pressure sensor in the two test benches is certified according to ISO 9001. The entire

Winter 2011 / 2012

Thermalia ® brine-water and water-water heat pumps

Belaria ® air-water heat pumps


I nsight s 16

In detail focus

Liechtenstein

A lot is new inside the company headquarters.

Hoval is rooted in tradition and geared toward innovation. This is apparent at the headquarters in Vaduz. The buildings for production and administration have grown steadily as the number of employees has increased. Certain interior sections were renovated and modernised this year. Further rebuilding measures are planned for 2012.

The long office building at the outskirts of Vaduz is as much a part of Hoval as the colour red is. From the outside, there is hardly an indication of the modifications and renovations that have been going on inside. The head office of the Hoval Group in Vaduz is home to Group Management and all corporate departments, from Research & Development to management of the Heating Technology and Climate Technology divisions. It also

holds the central departments of Information Technology and SAP, and Quality and Risk Management. Vaduz is one of the production locations of the Group. This is where, for example, hightech units involving condensation ® design and aluFer technology are manufactured. Around 50 new workplaces were gained through reallocation and reorganisation. These are workplaces that will above all benefit Research & Development and

Climate Technology. An interaction matrix was created by those responsible for the infrastructure to illustrate the communication paths of the various teams. The planning also took the forecasts for corporate growth into account. “Vaduz is and will remain the Hoval centre of expertise for the whole group. That’s why we are investing in the headquarters,” explains Fabian Frick, CEO Climate Technology and New Markets and Executive Board Hoval Group. In addition to the offices, the staff

Insights


In detail focus

Enhanced efficiency and quality due to new robots in the final assembly.

The lavishly appointed entrance area, the new meeting facilities and the updated staff restaurant are perfect examples for the successful refurbishment.

r­ estaurant has been fully redesigned and now meets employee needs. In spring 2012, an area for relaxation during the lunch break will be opened outdoors. Well-trained employees are a major competitive advantage, a fact that will be addressed by a new training centre in mid-2012. The practical training room is a teaching facility and showroom for technological competence and will be supplemented by a theoretical programme that will impart the necessary knowledge tailored to specific target groups. The “Hoval world” really begins behind the modified three-storey office building. A total of 20 halls and administrative buildings occupy most of the

Winter 2011 / 2012

campus. Their footprint of 55,000 square metres equals roughly eight football fields. “We implemented various optimisations here as well,” explains

“Vaduz is and will remain the Hoval centre of expertise for the whole group. That’s why we are investing in the ­headquarters.” Fabian Frick, CEO Climate Technology and New Markets and Executive Board Hoval Group

Thomas Graf, Director of Infrastructure and the Training Workshop.“ The procedures in final assembly were adjusted to the new Hoval product design.” He also

points out the two new industrial robots for welding and priming. “These were necessary to increase capacity and to be able to create production processes with greater efficiency.” In addition, there are two new ultra-modern test benches for heat pumps – described in detail on pages 14/15. The first hall in Neugut was erected on the green meadow in 1957. Over the next decades, this was followed by one hall after the other, making it possible for Hoval to promptly adapt its production capacity to the growing economy well before the competition could react. It was a wise move by company founder Gustav Ospelt who, with courage, faith and foresight, laid the cornerstone for a company that is passionate about technology.


I nsight s 18

In detail focus

In the supermarket of the future, freezers, refrigerators and the heat pump system will be linked with climate and ventilation technology to form a single overall system – both hydraulically and for control purposes.

EcoLine – saving energy in supermarkets

Clever supermarkets not only spare the consumers’ wallet but also that of the supermarket itself. Hoval does a lot to help. Below, “Insights” makes the calculations and shows how energy can be saved on a large scale. Thomas Feron is clear: “We are speaking about money – and a lot of money can be saved.” As the segment manager for EcoLine, the Hoval system solution for supermarkets, he calculates the savings for each individual project. But first this: “Saving energy in supermarkets is all about combining the cold for coolers, the heating system, the climate system and the ventilation in such a way that the individual components do not interfere with each other and waste energy. We combine them into a system in which all components are interlinked and managed in a controlled manner.” A specific example: A medium-sized 2 store with a sales area of 2500 m ­consumes – without EcoLine –

2 585 kWh per m and year for heating, climate control and ventilation, and for the refrigeration and freezing of food. The largest share, namely around half, is eaten up by the cooling systems. Fifteen percent are used for heating and climate control, 25% for lighting, and the remaining 10% are consumed by various other power consumers. The EcoLine system can reduce energy 2 consumption by 65% to 210 kWh per m and year. Thomas Feron’s conclusion: “Not only does EcoLine let the supermarket operator produce a good climate balance sheet. He also has more money in his pocket.”

This is a highly persuasive argument because profit margins in the food retail business are on the decline – while power costs are rising.

Hot summers with consequences The extreme summer heat that stifled Europe in 2003 was not a small matter. The exhaust heat from the condensers of coolers, which in many supermarkets are simply plugged into the power grid, heated up the sales areas even further. Especially in small stores without air conditioning, uncooled fresh foods spoiled. As a result, some discounters installed an air conditioning system to fight overheating with cooling – and ended up massively increasing power consumption. In winter, the heat exhaust from the coolers was blown outside while separate boilers generated heat. The independently operating components were each optimised separately, if at all. Instead of this scenario, the individual units can combined into an efficient overall system. Integrated

Insights


systems emerged in around 2005. Large discounters in Germany such as Rewe and Edeka invested in sustainable concepts with “green” cooling and climate technology. But they seemed to be missing an important feature: the purposeful control of the interactions between coolers and indoor climate control systems.

“We are speaking about money – and a lot of money can be saved.” Thomas Feron, EcoLine Segment Manager

A pacemaker for everything “For us it was the logical next step to develop an overall concept that combines all thermal and control-related processes,” reports Thomas Feron. The controller is essentially the pacemaker in the EcoLine system from Hoval. It optimises the interplay between the system parts and enhances their ­efficiency – ensuring that energy consumption and costs continue to fall. Enter the heat pump Another important component of the EcoLine system is the reversible heat pump. In summer, it produces the coldness needed during the day, while filling

Winter 2011 / 2012

the ice storage tank at night. The heat pump subcools the coolant in the coolers, increasing the COP (coefficient of performance) of the commercial refrigeration by around 50%. Thanks to the improved energy efficiency, ­refrigeration units can be downsized. In winter, the exhaust heat from commercial refrigeration supports the heat pump in heating the building. Once gain, the COP of the refrigeration units – and of the heat pump – can be ­optimised. In supermarkets with a floor 2 space up to 2500 m , the heat pump is sufficient for heating. Decentralised climate control units Dry air in front of the coolers relieves the climate control system. Hoval ® RoofVent decentralised climate control units that are distributed across the supermarket roof dehumidify the air and supply the room with outside air. Thanks to their integrated, high performance plate heat exchangers, they recover up to 84% of heat or coldness. The regulatable, patented Air-Injector vortex air distributor directs the warm air generated during heating vertically downward so it arrives exactly where it is needed. During cooling, the Air-­ Injector spreads the air out horizontally,

which can then sink across a large area. This prevents draughts. Thus, EcoLine includes even the seemingly smallest part into the system.

Rapid amortisation Already more than 100 super- and hypermarkets – primarily in France and Russia – are saving energy and money with the EcoLine system. A case study for an Intermarché supermarket in Marseille with a sales 2 floor of 2062 m , a storage area of 2 2 140 m and an entrance area of 50 m reports annual savings of 30,000 euros. Savings are generally so high that the additional investments are amortised within one or two years. Especially those franchises that operate on their own budget are pleased with EcoLine. These include partners of the supermarket chains Intermarché, E. Leclerc and Super-U, and hypermarkets like Auchan. Against this background, EcoLine is expected to continue to assert itself in Europe and Russia.


I nsight s 20

In detail focus

The first Hoval BioLyt wood pellet boiler was installed here in 1999.

BioLyt gets the most out of biomass

The BioLyt wood pellet boiler has long been suitable for more than just single family homes. This technology, which Hoval has been promoting for twelve years, has developed into a very powerful, flexible and of course environmentally friendly system. Wood is superior to oil even in terms of price. A coincidence? A situation that implies solidity? Whichever the case, these are the facts: In Tettnang in southern Germany, not far from Lake Constance, you will find the first large pellet boiler from Hoval. The community of Sankt Gallus had it installed several years ago as part of a local heating concept. A BioLyt (160) unit is cascaded with an ® UltraGas condensing boiler. In ­addition, 40 square metres of solar ­collectors supply energy that supports the heating system. With this concept, Sankt Gallus avoids an output of 70 tonnes of CO2 every year. For more information on the complete Hoval systems for local and district heating, see the info box on page 21. Tettnang is also the hometown of Daniel Hegele and his family. Since he joined the Hoval team in 1998 in Vaduz, he

has been occupied with biomass. And what does he heat his own house with? ”Of course with the first BioLyt model that we introduced to the market in 1999: with the BioLyt (14). Incidentally, all experience gained with this model was taken into consideration in the new BioLyt (50-70) model launched in 2006. As if a visible argument for the Hoval pellet boiler were still necessary: Daniel Hegele’s house is painted red, the window frames are bright white. Protect nature! Both Daniel Hegele and the church community of Sankt Gallus associate ethical values with the BioLyt. Changing to renewable energy means sparing nature and the environment. The latest example of this is the Triesen church in Liechtenstein – more details can be found on page 8. Today, two

kilos of pellets generate the same amount of heat energy as a litre of heating oil. Solid and compact In addition to its outstanding eco-friendliness, BioLyt is characterised by solidity, and that is everything but a coincidence at Hoval. It is a tradition. Solidity has always been an integral part of the Hoval approach to quality. The BioLyt (50-160) wood pellet boiler is so compact that it fits in the same space as the former oil heating system. “That’s astounding,” comments Daniel Hegele, “considering that biomass boilers usually require more space.” Hoval delivers the boiler body, external casing and controller individually, a highly advantageous policy in tight places. At the installation site, the parts can be assembled in just a few steps.


The connections are arranged as they are on an oil boiler: at the front and rear. This saves effort, time and costs during installation. Ideal for upgrades These advantages make the BioLyt the first choice – especially for house refurbishments and conversions of older properties. In addition, the unit features a sophisticated, space-saving technology for conveying wood pellets: they are sucked into the system. Incidentally, the pellets can be stored where the oil tank was previously located. Less expensive than oil Of course, the price, too, plays a role. Already today, heating with pellets is almost half as expensive per kWh of heat energy as heating with oil. A pellet boiler from Hoval will generally be amortised after just a few years.

“Our special strength is networking. All you need is a single line to the next house – and the heating system there can be taken out of service.” Daniel Hegele, Head of Development, Biomass

And comfortable, too The BioLyt self-cleans the heating surfaces and the burner. This lowers maintenance needs, and the ash can be easily eliminated with the rolling ash pan. Only 5 kg of ash are produced by 1000 kg of pellets: a clear argument for this modern combustion technology and its consistently high efficiency. Also ® convenient to operate is the TopTronic controller, which is used to regulate the entire system.

For larger buildings as well Wood and the practical wood pellets have developed into an intelligent ­alternative – even for multifamily homes, hotels and administrative and industrial buildings. The BioLyt (160) power output can be multiplied by ­coupling the units into double or ­multiple boiler systems. Networking and combining “Our special strength is networking,” Daniel Hegele adds. Both in Tettnang and in Triesen, several buildings are heating by a single system. All you need is a single line to the next house – and the heating system there can be taken out of service.“ Networking can also mean combining – for example with a gas boiler to cover peak periods or with a solar energy system to support the heating system without producing more CO2.

District heating – sustainable and investment-friendly energy source for the future. Schematic diagram of district heat energy Supply of public and private buildings with heat energy and hot water. Hot water

Hoval water heater Heating system

TransTherm District heating stations Hot water Heating system

Thermal energy is transported in a heat-insulated pipe system.

Today, the concept of everything from a single source is more than just a good reason for an investor, especially when it comes to complex projects that intend to use local District heat is energy with a future. and district heating networks or biomass. Hoval demonstrates competence in all areas – system Local and district heat is becoming increasingly ­planning,popular the optimal of products intoreason: efficient as annetworking energy source. With good systems, the andsupply service. The high quality TransTherm heat of energy via local or district heating transfer and districtisheating stationstofrom Hovaland offerusers networks more attractive investors than decentralised supply systems.

District heat is sustainable energy District heat is a valuable substitute for fossil fuels

Winter 2011 / 2012since it is often generated from local and renewable

energy sources. It may also take advantage of the waste heat generated as a by-product in industrial

District heat generation plant (e.g. waste incineration, wood chip plant, industrial waste heat).

c­ ustomised solutions for every requirement, ensuring that the energy is safely and reliably transferred to the building heating system with a very high level of efficiency. District heat is clean energy The range of applications is large: single family homes, ­multifamily homes, apartment blocks, office complexes The of heatwith in aenergy-intensive centralised plant reduces and generation industrial plants processes. pollutant emissions and lowers CO2 output. Efficient More onscrubbers Hoval transfer stations in your filters, country can be exhaust and high performance such found at used www.hoval.com. as those in central woodchip power plants or waste incinerators, considerably reduce the impact on the climate and environment compared to systems that generate heat individually in each building.

District heat is investment-friendly energy District heat provides a reliable energy supply and


I nsight s 2 2

In detail focus

Warehouse heating: quickly planned and implemented. Today, logistics halls must be able to adapt to their particular purpose.

With the complete solution from Hoval, warehouses of any size and height can be heated and ventilated. The system is modular and scalable. This simplifies planning and tendering, and shortens the project handling period.

Functional model of the Hoval solution with heat generators and a decentralised ­recirculating air heating unit

All units are turnkey-ready and fast ® to implement: the UltraGas double ® boiler unit, the TopVent recirculating air heating unit, and the TempTronic RC zone control system. Dual fuel solutions with a heat pump, pellet or wood chip boiler or solar thermal connection are also possible. Systems with dual fuel heat generation are especially significant in light of the Renewable Energies in the Heat Sector Promotion Act (EEWärmeG), with which Germany is driving the development of renewable energies forward. Optimal heat distribution in logistics warehouses is achieved by the ® TopVent recirculating air heating units mounted on the warehouse ceiling, distributed throughout the interior.

They take in the room air, heat it in the heating coil and blow it back into the room. For a directional and efficient introduction of warm air into the hall, ® each TopVent unit is equipped with an automatically adjustable vortex air ­distributor – the Air-Injector. It auto­ matically adjusts the range of the air jet (from 4 to 25 metres) to the height of the hall. The actual range of the air jet depends on the current air temperatures. The Air‑Injector is therefore ­automatically controlled by an algorithm contained in the TempTronic RC zone control system. Via the vortex ­mechanism, the unit also varies the scattering angle of the introduced air so that the warmth can be directed downward between the high racks in the hall. Temperature stratification in the hall can

thus be limited to 0.15 Kelvin per ­mounting height meter. In contrast, ­conventional warm air heating systems often operate with a stratification of up to 1.0 Kelvin per metre. Thanks to the low temperature stratification, heat cushions cannot form under the roof, a common issue in halls. Considerably less heat is lost as a result. In addition, the heating times and the temperatures can be individually regulated with the zone controller – yet another way to save energy. The ® TopVent recirculating air heating units are so efficient that the Hoval solution makes do with fewer units and smaller air volumes. Overall, this lowers the investment, installation and operating costs.

Insights


I nsight s 23

In retrospect focus

The first Hoval in-house newsletter from 1955

The aim of the Hoval in-house newsletter of 1955 was to promote and create a healthy corporate climate. Gustav Ospelt attached great importance to the flow of information within the company and between the company and family members at home. Also, even then, the new medium was used as a vehicle of communication with the public. The first Hoval Newsletter appeared on 20 December 1955 under the title of “Hauszeitung Gustav Ospelt Vaduz”. The text was typed and then printed using a simple transfer printing method. It was set in the purple colour of the matrices typical for that time. The first page showed a simple drawing of the Vaduz Castle with a stylised version of the Hoval signet and the occupational symbols of a gear wheel, anvil, compass, hammer and tube. The title and the gear wheel were printed in red. The first edition contained 6 pages that were printed on one side only. At the time, the company had a staff of 111 employees. One hundred and thirty copies of the paper were printed.

Winter 2011 / 2012


Hoval Aktiengesellschaft

4211147-12/2011

Austrasse 70 9490 Vaduz, Liechtenstein www.hoval.com

Legal

“Insights” – the Hoval Group magazine for customers and employees. Appears biannually at varying times. Responsible: Marketing Services, Hoval Aktiengesellschaft, 9490 Vaduz, Liechtenstein.


Insights 2/2011