Perfection for the bathroom

  • CUSTOMER

    Bette GmbH & Co. KG

    PROJECT

    Supply of completely oil-free compressed air for reliable enamelling of high-quality bathroom elements

  • CUSTOMER

    Bette GmbH & Co. KG

    PROJECT

    Supply of completely oil-free compressed air for reliable enamelling of high-quality bathroom elements

  • CUSTOMER

    Bette GmbH & Co. KG

    PROJECT

    Supply of completely oil-free compressed air for reliable enamelling of high-quality bathroom elements

PROJECT INFOS

How a premium manufacturer of bathroom elements ensures product quality

The challenge
As part of a complete replacement of their existing compressed air system, Bette was looking for a cost-efficient solution which would guarantee future process reliability. This involved ensuring the reliable supply of high-quality air for metalworking and totally oil-free compressed air for the sensitive enamelling process.

The BOGE solution
With two screw compressors taking turns to provide the base load and one additional unit for support during peak demand, BOGE has guaranteed this company no longer needs to worry about their compressed air supply. The BOGE bluekat converter provides consistently oil-free class 0 purity compressed air for the enamelling process. The use of redundant components ensures the highest levels of process reliability. The new system even excels thanks to its excellent cost-effectiveness due to efficient heat recovery and a reduction in energy costs.

The result
A completely reliable solution offering minimal maintenance and maximum quality, reliability and safety security against oil leakage.

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    Bathroom elements in different shapes and colours – Bette GmbH & Co. KG from the town of Delbrück in Germany manufactures premium baths, shower areas, shower trays and washbasins from glazed titanium steel. The production process has some highly demanding requirements for compressed air. The supply of completely clean, dry and qualitatively high-performance compressed air at Bette is guaranteed by BOGE S132-4 L and S100-3 screw compressors. The downstream BOGE bluekat converter provides oil-free class 0 purity compressed air according to ISO 8573-1 for the enamelling process. Ultimately, Bette can enjoy highly reliable and efficient equipment with the highest levels of safety.

     

    “Fascinated by high-grade steel” – that’s how German company Bette describes the motivation and passion it feels for the manufacture of high-precision bathroom elements. Their baths, shower areas, shower trays and washbasins undergo a very special manufacturing process involving glazed titanium steel which is moulded under pressure and refined with a thin, glass-like coating. The combination of automated production and craftsmanship results in a truly tailor-made end product, with the customer able to choose from a range of 600 different colours and numerous special features. The company’s production and office buildings in Delbrück in Germany employ 385 co-workers at the family business Bette, which last year achieved a turnover of €83 million.

     

    Facing a loss of process reliability

    A supply of high-quality compressed air is one of the building blocks for an efficient production process at Bette. The compressed air is needed as both supply air for metalworking and as part of the enamelling process for the titanium steel elements. It is essential that this air is absolutely oil-free at all times. At the start of the 1990s, the premium bathroom element company operated four compressors from different manufacturers in order to achieve the required free air delivery. When one of the devices failed, the remaining three had to step up to provide the necessary pressure: “Those compressors were really at the end of their useful lives. If we’d had any other issues, we would have had to step down production, says Udo Bartels, operations manager at Bette GmbH & Co. KG. “We no longer had any redundancy in the system, so we needed to look for a cost-efficient solution which would guarantee future process reliability.” Initially, the company opted to lease an additional compressor, however, this resulted in increased overall running costs. In 2017, Bette decided to replace all the existing compressors with BOGE screw compressors, microfilters and the BOGE bluekat converter after having seen the compressed air technology the company could provide.

     

    “As one of the leaders in the sector, we decided to go with BOGE,” explains Udo Bartels. But there was also a long-standing mutual trust between the partners: “The fact the company also belongs to the local it’s OWL technology network definitely affected our decision to opt for BOGE.” Just like Bette, BOGE is also closely linked to the local area and works in conjunction with other companies and universities to ensure that the Ostwestfalen-Lippe region in Germany remains one of the leading machine building areas of Europe.

     

    Screw compressors provide reliable compressed air

    Bette’s new compressed air system started up in 2018. Two S132-4L screw compressors take turns to provide the base load, with an additional S100-3 screw compressor providing pressure during peak demand. 60 percent of the compressed air is required for the enamelling process. The company’s top priority is to have constant high-quality compressed air, particularly during the enamelling process. “We need high reliability and targeted supply capacity,” explains Udo Bartels. “Pressure variations in the supply network are undesirable as they can lead to constant interruptions in the spraying process and even a negative effect on the enamelling finish.” The spraying of the enamel layer can become uneven, resulting in a reduction in quality of the final product. Thanks to the use of BOGE screw compressors, however, this issue can be completely ruled out. The S132-4L compressor with downstream microfilter and refrigerant dryer reliably produces clean, dry and technically oil-free compressed air of consistently high quality. The high-performance filter reduces the residual oil content of the compressed air to just 0.01 mg/m³. Thanks to the dryer, the system has a pressure dew point of 3°C, a prerequisite for the safeguarding of the production process.

     

    Ensuring oil-free air

    Spray arms apply the enamel to the products, just like spray painting. Unlike painting, however, coating with enamel requires a higher pressure of 8 bar to ensure correct atomisation. For this extremely sensitive manufacturing step, Bette requires 100% oil-free air. Should any oil get onto the steel carrier layer, the enamel will no longer adhere to the product and the entire process has to be interrupted. Once inside, oil will also rapidly contaminate the entire system. All pipework will need to be cleaned thoroughly, resulting in increased costs. In short: oil getting into the system can endanger operations. This risk can be mitigated by with the help of the BOGE bluekat converter BC210 which ensures consistent class 0 compressed air quality. The converter turns the oil into carbon dioxide and water, and can do so across a wide range of different temperatures or moisture content for the compressed air to be produced. The residual oil content in the compressed air never exceeds 0.003 mg/Nm3 – regardless of the quality of the intake air. For redundancy, there is also a BOGE DCZ126-2 activated carbon adsorber which can be used to ensure oil-free compressed air when maintenance work is being carried out on the converter.

     

    Absolute safety and efficiency

    The BOGE bluekat converter comes with overload protection which cannot be exceeded. This is in contrast to other treatment processes in which a failure in oil separation can result from improper maintenance or saturation of the filters. The BOGE bluekat converter guarantees absolutely oil-free compressed air, as there is no chance of oil leakage. The entire system at Bette is designed with safety in mind: in addition to the activated carbon adsorber, a second refrigerant dryer is also available to ensure redundancy. As a result, the entire system can even undergo maintenance while still in operation. The BOGE screw compressors are designed to run at optimum energy usage, meaning that Bette has been able to achieve additional energy savings of up to 10 percent thanks to their new compressed air system.

     

    The new system also offers further cost savings and even contributes to the overall environmental footprint of the manufacturing process at Bette: the heat generated as a by-product of producing compressed air is used efficiently as both process heat and to warm the manufacturing areas and administration building. At BOGE, heat recovery is designed to be an integral part of any system. And in the case of Bette, heat recovery provides additional support to the cogeneration unit, reducing the running time of the natural gas boiler by around 30 percent.

     

    Proudly displaying the right colours

    “BOGE provided unparalleled support during the entire product implementation phase; the service they provide is both competent and solution-driven,” says Udo Bartels. “Thanks to the BOGE bestcair service program, we can also expect optimum dependability and consistent efficiency levels for our system going forward.” BOGE guarantees both the motor and the airend for a period of five years, during which it also undertakes to replace any wearing parts with BOGE originals and guarantees that any maintenance work will be carried out by certified service technicians. “We have proven our strong bond with BOGE and our happiness with the overall system with a little thing we decided to do,” tells us the operations manager with a wink. “As the converter was grey and the compressed air storage system was zinc-plated when they arrived, we decided to quickly repaint these components.” Now, the entire compressed air system at Bette proudly stands out in typical BOGE blue.

     

    Read more about Bette GmbH & Co. KG:
    https://www.my-bette.com

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