The carbon-neutral Green Factory

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Carbon-neutral production is possible! Combine photo voltaic panels, a thermal power station, pellet heating and a production process aligned with the energy the system generates.

In 2019, Alois Müller GmbH in Allgäu opened their Green Factory in Ungerhausen, Germany. The Green Factory is a practically energy self-sufficient office and production building manufacturing heating and ventilation facilities as well as components for metal constructions. Over 200,000 solar cells on the roof provide two-thirds of the carbon-neutral electricity which is used directly onsite. Surplus electricity flows into the grid.

Production steps are aligned with the quantity of electricity available. High-powered electrical machines such as the laser are prioritized when the PV facility provides enough electricity. The same applies to lacquer and sandblasting work as well as production entailing various mediums such as liquid nitrogen, purified water and compressed air.

An important step toward carbon-neutral production is analyzing all material and energy flows required for manufacturing. An ERP system balances incoming orders and production data with the current weather prognoses. On days when there is not sufficient sunshine, the Green Factory draws its energy from a thermal power station. Additional energy is also supplied by a wood pellet boiler during extended cold periods.