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Editorial 

Energy in transition: progress despite obstacles 

Hydrogen Technology World Expo 2025 in Hamburg once again demonstrated the potential of hydrogen technologies 

– but also how much the industry continues to struggle with structural and political barriers. Numerous exhibitors 

presented impressive developments, such as scalable electrolysis systems and more efficient power conversion 

concepts. However, many discussions revealed a central concern: bureaucratic requirements and lengthy approval processes 

are noticeably slowing down implementation. Even where technologies are ready for the market, there is often a 

lack of predictable planning conditions, reliable funding structures and fast decision-making processes. 

The issue of financial viability was also a key topic. Despite progress, the costs of electrolysers, transport infrastructure 

and hydrogen storage remain high. Several exhibitors emphasised that business models are only viable if subsidy programmes 

are made permanent, grid fees are clearly regulated and purchase guarantees are created. The Expo thus 

made it clear that although 2025 marks a phase of technological maturity, without political determination, scaling will 

stall. 

At the same time, the biogas industry in Europe is at a critical turning point. On the one hand, demand for renewable 

gases and awareness of the advantages of regional circular economies are on the rise. On the other hand, the industry 

is facing increasing requirements – from stricter emission standards and complex sustainability certifications to volatile 

subsidy mechanisms. Many operators are struggling with investment uncertainty, especially when it comes to converting 

and expanding their plants. Profitability remains fragile as rising capital costs, uncertain gas prices and pressure for 

additional decarbonisation interact closely. 

In addition, biogas is regulated very differently across Europe, which makes market integration difficult. While biomethane 

is promoted as a key technology in some countries, it is met with political reluctance in others. This fragmentation 

hinders scaling and has a direct impact on investment decisions. 

The Biogas Convention 2025 in Nuremberg, which will take place from 2 to 4 December 2025, will therefore focus not 

only on technical progress, but above all on the need for action: How can approval procedures be accelerated? How can 

remuneration and subsidy models be stabilised? And how can a harmonised European market for renewable gases be 

created? At the same time, innovative solutions in the areas of fermentation optimisation, gas processing and digitalisation 

should demonstrate that the technical potential is there – provided that the regulatory framework grows with it. 

Whether hydrogen or biogas: the renewable energy world faces a double challenge. Technologies are developing 

rapidly, but political uncertainties, bureaucracy and financial risks are jeopardising the necessary speed. 

I wish you an interesting read! 

Silke Watkins 

GREEN EFFICIENT TECHNOLOGIES 2025 

3

GREEN EFFICIENT TECHNOLOGIES 

Contents 

Cover 

Redefining wastewater sludge transport 

Powering performance, efficiency and sustainability worldwide 

Across the globe, wastewater utili ties face a common challenge: how 

to transport thick, dewatered sludge reliably, economically, and sustainably. 

Traditional systems such as piston pumps and screw conveyors 

have long been the standard, but they come with high energy 

demands, costly main tenance, and operational complexity. In an era 

defined by sustainability goals and tightening budgets, water utili ties 

are searching for smarter alternatives. 

Contents 

Editorial 

Energy in transition: progress despite obstacles 3 

Cover story 

Redefining wastewater sludge transport 5 

Efficient handling of energy gases 

Heat recovery from the storage tank 9 

Driving forces in biogas operations 12 

CO 2 Liquefaction – Sustainability through modern gas technology 15 

Wire mesh as a key to cost reduction in hydrogen production 17 

The safe way to transport hydrogen – with the MEGC container 20 

Energy recovery 

Up and away with Bergzeit 22 

Energy-efficient heating 

Green district heating for Giessen 25 

Energy-efficient production 

On the way to becoming energy self-sufficient 29 

Companies – Innovations – Products 33 

Brand name register 38 

Index of Advertisers 38 

Impressum 

Publisher 

Dr. Harnisch Verlags GmbH 

© 

2025, Dr. Harnisch Verlags GmbH 

Responsible for content 

Ottmar Holz 

Silke Watkins 

Publishing company and reader service 

Dr. Harnisch Verlags GmbH 

Eschenstr. 25 

90441 Nuremberg, Germany 

Tel 0911 2018-0 

Fax 0911 2018-100 

E-Mail get@harnisch.com 

www.harnisch.com 

Errors excepted 

Reprinting and photomechanical reproduction,even 

in extract form, is only possible with 

the written consent of the publishers 

Editors 

Silke Watkins 

Advertisements/Brand name register 

Silke Watkins/Matti Schneider 

Technical Director 

Armin König 

ISSN 2752-2040 

4 

GREEN EFFICIENT TECHNOLOGIES 2025

Cover story 

SEEPEX Smart Air Injection – 

Redefining wastewater sludge transport 

Powering performance, efficiency and sustainability worldwide 

Hetlingen WWTP, northwest of Hamburg, Germany, seen from above, right next to the famous Elbe River. 

Image: SEEPEX 

Across the globe, wastewater utilities 

face a common challenge: how 

to transport thick, dewatered sludge 

reliably, economically, and sustainably. 

Traditional systems such 

as piston pumps and screw conveyors 

have long been the standard, 

but they come with high energy 

demands, costly main tenance, and 

operational complexity. In an era 

defined by sustainability goals and 

tightening budgets, water utilities 

are searching for smarter 

alternatives. 

SEEPEX, a global leader in progressive 

cavity pump systems and digital 

solutions, has positioned itself 

at the forefront of this transformation 

with its Smart Air Injection (SAI) 

techno logy. By combining progressive 

cavity pumping with densephase 

pneumatic conveying, SAI has 

proven to reduce energy consumption, 

lower maintenance costs, and 

streamline sludge handling over 

long distances and challenging pipe 

routing. Around the world, pioneering 

water utilities have adopted this 

approach and achieved measurable, 

lasting results. 

Fig. 1: SAI system loaded from mobile centrifuge 

with dewatered sludge. Image: SEEPEX 

The challenge of 

conventional transport 

Wastewater treatment plants 

(WWTPs) generate vast amounts 

of sludge that must be stabilized 

and dewatered. This is followed by 

targeted processing, such as drying 

and thermal utilization, with the 

goal of recovering energy and making 

valuable components usable. Conventional 

transport systems often 

rely on piston pumps operating at 

high pressure, requiring heavy-duty 

pipelines and subjecting equipment 

to accelerated wear. Mechanical conveyors 

often involve multiple steps, 

take up valuable space, and expose 

operators to rain-induced rehydration, 

odor and safety risks. 

The drawbacks are clear: high 

operating costs, frequent downtime, 

and environmental burdens that run 

counter to the water utilities’ sustainability 

objectives. The need for more 

energy-efficient, low-maintenance, 

and environmentally friendly technology 

is pressing. 

GREEN EFFICIENT TECHNOLOGIES 2025 5

Cover story 

The SEEPEX solution 

SEEPEX’s Smart Air Injection system 

delivers exactly that. By forming 

sludge into plugs, coating 

them with a thin polymer film, 

and propelling them forward with 

low-pressure compressed air, the 

system minimizes friction and significantly 

reduces pipeline pressure 

requirements. 

Compared to piston pumps that 

may run at up to 70 bar, SAI systems 

typically operate at only 2–3 bar. This 

reduces energy demand by up to 

80 % and extends the service life of 

pump components. 

Another critical advantage is simplified 

maintenance. With innovations 

such as the Rotor Joint Access 

system, operators can perform quick 

interventions without dismantling the 

pump, reducing maintenance costs 

by up to 88%. The pump system’s 

modular design allows for easy integration 

into existing infrastructure, 

whether for temporary projects or 

permanent installations. 

How SAI works in practice 

The principle behind SAI is simple 

yet highly effective. First, sludge is 

fed into an open hopper progressive 

cavity pump, which forms the material 

into dense plugs. These plugs 

are then coated with a thin layer of 

polymer lubricant at only approx. 

0.1 % dilution. Importantly, SAI uses 

this lubricant in extremely small 

quantities — just approx. 2 % of the 

overall sludge flow — making the 

chemical input negligible while significantly 

reducing friction inside the 

pipeline. Once lubricated, the plugs 

are propelled forward by controlled 

bursts of compressed air. Instead of 

continuous high-pressure pumping, 

sludge moves in short, efficient segments, 

reducing wear and cutting 

energy consumption. 

A complete SAI system typically 

consists of four main components: 

an open hopper pump to feed and 

compact the sludge, a dosing pump 

to supply the lubricant, a compressor 

with an air receiver vessel to 

generate the required low-pressure 

Fig. 2: SAI control unit and air receiver vessel. 

airflow, and the SAI controller. The 

controller is the “brain” of the system, 

managing air injection timing, 

lubricant dosing, and pipeline pressure. 

Advanced automation and 

monitoring features give operators 

real-time data and precise control, 

ensuring stable performance under 

changing conditions. 

Compared to piston pumps, 

which require up to 70 bar of 

operating pressure and wear rapidly 

under abrasive sludge conditions, 

SAI works at just 2–3 bar. This makes 

it possible to use lighter PN10 pipelines 

instead of expensive heavy-duty 

PN40–PN100 pipes, reducing both 

capital and operating costs. In contrast 

to bulky screw or belt conveyors 

that consume floor space, demand 

constant maintenance, and leave 

sludge exposed to the open air, SAI 

is compact, enclosed, and odor-free. 

The result is a system that not 

only reduces pressure but also 

reduces stress — on equipment, 

operators, and budgets. With lower 

wear, fewer spare parts, and optimized 

energy input, SAI makes 

dewatered sludge transport more 

predictable, more sustainable, and 

far more cost efficient. 

Image: SEEPEX 

Success stories from 

around the world 

Eco-Energy Plant, China 

When an ambitious eco-energy 

facility was launched to convert 

370,000 tons of municipal solid waste 

into 200 million kWh of electricity 

annually, sludge transport became 

a critical bottleneck. The layout 

required moving material 370 meters 

horizontally and 30 meters vertically. 

Traditional conveyors and trucks 

proved labor-intensive and costly, 

while dry sludge pumps suffered 

from wear due to excessive pressure. 

The installation of SEEPEX SAI 

transformed operations. The plant 

achieved smooth, trouble-free transport 

without replacing a single wear 

part. The results included up to 80% 

lower electricity consumption and 

major reductions in truck transport 

and labor costs, all within a compact 

footprint that fit the plant’s spatial 

limitations. 

Sydney Water WRRF, Australia 

Sydney Water, Australia’s largest 

water utility, needed a temporary 

solution to maintain operations 

during facility upgrades at its West 

6 


Cover story 

Camden plant. Conventional screw 

conveyors required extensive infrastructure 

and created odor challenges. 

SEEPEX’s mobile SAI system 

provided a compact, enclosed, and 

energy-efficient alternative. 

Performance tests confirmed that 

SAI maintained biosolids consistency, 

minimized odors, and streamlined 

transport. As Principal Engineer Mark 

Ziogas noted, “Implementing SEEPEX 

Smart Air Injection at West Camden 

WRRF has been a transformative step 

in biosolids management. This innovative 

technology not only enhances 

efficiency and reduces costs but also 

significantly improves safety and 

environmental outcomes.” The success 

of the temporary application 

has spurred Sydney Water to explore 

permanent deployments across its 

network. 

Hetlingen WWTP, Germany 

Serving more than 40 municipalities 

north-west of Hamburg, Hetlingen 

WWTP needed to replace undersized 

piston pumps that consumed excessive 

energy and required frequent 

maintenance. The challenge was to 

transport 5–15 m³/h of dewatered 

sludge over 90 meters, including a 

30-meter vertical rise. 

SEEPEX supplied a turnkey SAI 

solution, including a hopper pump, 

a compressed air system, a dosing 

pump, and automation control. By 

operating at just 2–3 bar instead of 

70 bar, Hetlingen reduced pipeline 

requirements and cut energy use by 

Fig. 3: Boundary layer and air injection ports. 

20–25%. Maintenance was simplified 

with easy access to key components, 

reducing downtime. The plant now 

enjoys smoother operations with a 

lower carbon footprint. 

Sehnde WWTP, Germany 

In Sehnde, near Hanover, sludge was 

previously transported using a piston 

pump that required high energy input 

and costly maintenance. The goal was 

to reduce energy use, lower operating 

costs, and ensure compliance 

with new environmental regulations. 

SEEPEX installed an SAI system 

capable of moving sludge 250 meters 

through an existing buried steel pipeline. 

Within the first year, energy 

Image: SEEPEX 

costs were reduced by more than 

50 %, while maintenance costs fell by 

88 %. Operating pressures dropped 

from 60–80 bar to just 3 bar. Overall, 

annual operating costs were reduced 

by up to 82%, saving around € 37,500 

per year. This success demonstrated 

the scalability and sustainability of 

SAI as a future-proof solution. 

Clear, Measurable Benefits 

Across these diverse projects, several 

recurring benefits stand out: 

• Energy Efficiency: Up to 80 % 

reduction in energy consumption 

compared to piston pumps. 

Fig. 4: Smart Air Injection system featuring an open hopper pump, boundary layer injection, and control unit for optimized biosolids transport. 

 

Image: SEEPEX 

GREEN EFFICIENT TECHNOLOGIES 2025 7

Cover story 

Fig. 5: SAI including compressed air connections and lubricant injection points. 

Image: SEEPEX 

• Maintenance Savings: Up to 88 % 

lower maintenance costs thanks to 

low-pressure operation and simplified 

pump access. 

• Reliable Long-Distance Transport: 

Confident handling of dewatered 

sludges up to 1 km and vertical 

lifts. 

• Compact and Flexible: Modular 

design suitable for both temporary 

and permanent installations, 

requiring less footprint. 

• Environmental Protection: 

Enclosed pipelines reduce odors 

and emissions, supporting workplace 

safety and sustainability 

goals. 

A global standard for the future 

From China to Australia to Germany, 

Smart Air Injection has consistently 

proven itself as the future of 

sludge transport. By addressing the 

inefficiencies of conventional systems 

and delivering measurable 

gains in energy savings, cost reduction, 

and sustainability, SEEPEX has 

set a new benchmark for the wastewater 

sector. 

In a time when utilities are under 

pressure to meet growing demand, 

reduce carbon emissions, and optimize 

limited resources, SAI provides a 

pathway to achieve these goals. With 

more than 100 installations worldwide 

and counting, the system has 

already established itself as a trusted 

solution across multiple contexts. 

As the megatrend of sustainability 

reshapes industries, the message is 

clear: Smart Air Injection is not just 

an incremental improvement — it is a 

step change. By combining engineering 

excellence with real-world results, 

SEEPEX is enabling wastewater utilities 

to embrace a cleaner, more efficient, 

and future-ready approach to 

sludge handling. 

SEEPEX GmbH 

Bottrop 

www.seepex.com 

8 



Heat recovery from the storage tank 

Dr. Michael Golek 

GEA has invested twelve million euros in the British company Caldera. The photo shows the Caldera factory. 

Image: Caldera 

Industrial heat pumps are crucial 

for the decarbonization of industrial 

heat demand between 100 and 

200 °C in industries such as food 

production, dairy production, breweries, 

distilleries and the pharmaceutical 

sector. In a holistic concept, 

smart thermal storage can be combined 

with heat pump technolo gy to 

offer industrial customers a competitive 

and reliable option for all-electric 

and therefore low-carbon 

process heat supply. The machine 

and plant manufacturer and solution 

provider GEA has therefore 

invested in the British company 

Caldera, which has developed intelligent 

thermal storage systems. 

The thermal store as a 

digital grid juggler 

The energy transition is much more 

than just the construction of new 

wind turbines and solar plants. It is 

a gigantic digital and logistical challenge 

that is forcing us to rethink our 

energy system from the ground up. 

We are looking for intelligent solutions 

that can tame the fluctuations 

of renewable energies and keep the 

grid stable. And sometimes the brilliant 

idea comes from a direction that 

is not immediately on the radar: from 

Fig. 1: Caldera has developed electric storage 

boilers that can store electricity in the form 

of heat, which can be retrieved when needed. 

 


good old heat. We know the scenario: 

on a stormy day, the wind turbines 

are turning at full speed, the sun is 

shining on the photovoltaic systems 

and suddenly there is too much electricity 

in the grid. Prices fall, sometimes 

even into negative territory. 

In the worst-case scenario, the wind 

turbines have to be throttled back to 

avoid overloading the grid. 

Load shifting, peak shaving and 

grid benefits 

This is where Caldera’s intelligent 

thermal energy storage systems 

come into play. With the “Storage 

Boilers”, Caldera has developed a 

technology that converts electricity – 

ideally from renewable sources such 

as solar and wind – highly efficiently 

into industrially usable process heat. 

The key feature: a special storage 

core made of volcanic rock and recycled 

aluminum is heated up to 500 °C 

using electricity. Specially developed 

vacuum insulation ensures that this 

heat can be conserved for days or 

even weeks to supply steam, hot 


9


technical and economic influencing 

factors. 

On the technical side: 

When it comes to thermal storage, 

there are two physical properties that 

are of particular interest. Firstly, there 

is the heat storage capacity, i.e. the 

amount of energy that can be stored 

per volume or mass. This is very good 

for both materials. The thermal conductivity 

is also important. It ensures 

rapid absorption but also release of 

heat and therefore optimum energy 

throughput of the storage unit. Aluminum 

stands out here and the 

casting process creates a close connection 

to the lava rock and thus a 

very good heat transfer. 

Fig. 2: Heat is generated inside the boiler: The heat cell is the innovative component in every 

Caldera storage boiler that enables intermittent renewable energy to be converted into heat 

on demand. The blocks made from Caldera’s patented heat storage material are quickly 

assembled on site and enclosed in a vacuum-insulated chamber. 


water or hot air for industrial processes 

as required. This shifts large 

energy packages – from the electri- 

city grid – into a heating network. This 

relieves the electricity grid in times 

of high feed-in from renew able energies 

and avoids overloads or curtailment 

of renewable plants. At the 

same time, the electricity is used 

when it is available in abundance, 

which increases the efficiency of the 

overall system. It helps to smooth the 

load curve and reduces the need to 

switch on expensive peak-load power 

plants. 

The combination of lava rock 

and aluminium scrap is the result of 

an optimization task between both 

On the economic side: 

Although there are materials that 

show better properties in terms of 

storage capacity and conductivity, 

the purchasing costs for lava rock 

and aluminum scrap are compelling. 

You could buy lava rock in virtually 

any DIY store. The price of aluminum 

scrap benefits indirectly from 

the increasing population of electric 

cars. The supply of aluminum scrap 

from engine blocks from combustion 

engines is increasing, which means 

that the price will continue to fall in 

the long term. Furthermore, there 

are no shortages of either material 

on the international markets and 

they are non-toxic. Insulation is provided 

by a double-walled vacuum bell 

housing and the overall efficiency is 

around 95 percent. 

Provision of flexibility and 

balancing energy 

Fig. 3: Decarbonization of industrial process heat: GEA heat pumps and Caldera storage 

boilers complement each other. 

Graphic: Caldera 

The storage system’s rapid adaptability 

makes it a valuable player 

on the balancing energy market. 

By converting electrical energy 

into thermal energy and storing it 

locally or close to consumption, the 

Caldera storage system decouples 

the demand for electricity from the 

demand for heat at certain times. 

This reduces the need for transport 

capacities in the electricity grid for 

heat generation and creates free 

capacities for further feed-in from 

renewable energies. 

10 GREEN EFFICIENT TECHNOLOGIES 2025


In addition, the storage system is 

connected to the spot markets via an 

intelligent energy management system. 

When prices on the electricity 

markets fall due to high wind or solar 

production, sometimes even into 

negative territory, the storage system 

fills up – sometimes for fractions of 

a cent per kilowatt hour, sometimes 

with proceeds for purchasing (dayahead 

and intraday trading). 

The real game changer, however, 

is participation in the balancing 

energy market. The ability of a 

large thermal storage facility to flexibly 

absorb electricity in a matter of 

seconds is invaluable for stabilizing 

the electricity grid. The transmission 

system operators pay for this. A company 

that offers its storage facility on 

the market for automatic frequency 

restoration reserve (AFR) generates 

additional income that can massively 

reduce the effective electricity 

procurement costs for heat generation 

– in some cases even into negative 

territory. As a result, the effective 

electricity price for the process heat 

generated – a mix of cheap in-house 

electricity, spot market bargains and 

revenues from grid stabilization – can 

be cheaper for industrial and commercial 

companies than the price of 

gas. This was already the case in 2023 

and 2024, when the energy markets 

were turbulent. The volatility of the 

electricity market, which many see as 

a risk, becomes a source of income 

here. 

The Author: 

Dr. Michael Golek 

GEA Group AG 

Ulmenstraße 99 

40476 Düsseldorf, Germany 

Tel.: +49 (0)211-9136-0 

michael.golek@gea.com 

www.gea.com 

More information about Caldera: 

https://www.caldera.co.uk/ 

In conversation 

Kai Becker 

CEO of the GEA Heating and 

Cooling Technology Division 

“At GEA, we are committed to playing 

a leading role in the net-zero 

transition of the process industry. 

Our industrial heat pumps are already 

an important alternative to 

fossil fuel boilers and enable the 

decarbonization of process heat 

up to 95°C. With the investment in 

Caldera, we are adding a powerful 

complementary solution that 

means two things: First, together 

we can decarbonize process 

heat up to 185°C. Secondly, GEA’s 

heat pumps and Caldera’s storage 

systems bridge the gap between 

variable power generation from 

renewables and fluctuating industrial 

heat demand. With GEA’s 

global presence and expertise in 

process and industrial heat, we 

can accelerate the adoption of 

these combined solutions for industry 

worldwide.” 

James Macnaghten 

CEO of Caldera 

“The collaboration with GEA is 

a ground-breaking oppor tunity 

for our company and a strong 

endorse ment of our technology. I 

am convinced that the partnership 

with GEA, and in particular the use 

of GEA’s extensive experience, will 

help to deploy our storage boilers 

in even more companies such as 

breweries, distilleries, the dairy industry 

and the food and pharmaceutical 

industries, with the aim 

of reducing CO 2 emissions for the 

benefit of all.” 


11


Driving forces in biogas operations 

Blower technology for gas transport and CO 2 liquefaction 

Expansion stage of the biomethane plant operated by NordFuel GmbH in Friesoythe, due to be completed by March 2025. Almost half of the 

construction project has been completed. 

Image: Continental Industrie 

Friesoythe is home to one of the 

most modern biomethane plants 

in Europe, where NordFuel GmbH 

operates a state-of-the-art biogas 

plant that produces valuable biomethane 

from one million tons of farm 

manure per year. One of the biggest 

challenges is loss-free processing, 

an area in which high-performance 

blowers, such as those manufactured 

by Continental Industrie in 

Dormagen, play a pivotal role. 

Pick-up and delivery service 

included 

The delivery of farm manure is a 

precisely timed process: NordFuel 

GmbH trucks collect approximately 

80 % solid matter from manure produced 

by hoofed animals and poultry, 

and around 20 % liquid manure from 

livestock farmers in the surrounding 

area. Manure is collected from all 

Fig. 1 shows the delivery of farm manure from the surrounding area to the substrate hall. The 

company's own lorries collect the material from all agricultural businesses, thus ensuring that 

the company premises are kept clean. 


farms with a contract with the company. 

After separation, the liquid 

portion is returned to ensure pumpability, 

which is a resource-saving 

process. A fully digitalized incoming 

inspection process using QR 

codes ensures efficient operations 

and comprehensive documentation. 

Truck drivers always know which gate 

of the huge substrate hall to drive to 

in order to unload. 

This is divided into sections 

so that each type of substrate can 

be separated from the others and 

stored temporarily for processing 

according to the first-in-first-out principle. 

Inside the hall, fully automatic 

cranes transport the material to the 

appropriate bunkers as required. 

From there, it is transported to the 

individual fermenters via screw conveyors. 

“Different types of manure 

offer different gas yields, which is a 

decisive factor taken into account 

from the outset in continuous feeding,” 

emphasizes Andrea Schneider, 

assistant to the management. “The 

entire plant is designed so that 

nothing is wasted. Every detail has 

been planned so that we can produce 

with maximum efficiency.” 


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Fig. 2: Tobias Boeckh, Managing Director of Continental Industrie GmbH, Project Manager Niklas 

Hense from revis bioenergy and Jens Steller, Interim Operations Manager of the biogas plant (from 

left) next to the two redundant large industrial blowers from Continental Industrie in the biogas processing 

plant. These blowers ensure the necessary stability in the downstream cleaning and separation 

process. 


No odor lingers in the air 

Another key element is the exhaust air 

purification system. First, the contaminated 

air is treated with sulphuric acid to 

filter out ammonia. It then flows through 

a biofilter to minimize any remaining 

odors. This process produces an ammonium 

sulphate solution (ASL) that can 

later be used as fertilizer. Moistened 

wood chips in the biofilters break down 

odor components, optimizing the cleaning 

performance to ensure that the 

cleaned, odor-free air escapes through 

the exhaust chimney. This protects the 

entire site from unpleasant odors. 

Movement in gas processing 

The raw gas streams from the fermenters 

converge at the biogas upgrading 

plant. Here, two large Continental Industrie 

451 blowers are used to enable processing 

into bio methane. With five stages 

and powerful 110 kW motors, the blowers 

are designed to be energy efficient. 

The plant can process up to 7,500 Nm³ 

of raw gas per hour, and the biogas is 

enriched to 99.6 % methane via pressure 

swing adsorption. 

Using large blowers was a deliberate 

choice: “Energy efficiency is our top 

priori ty. Smaller blowers would have 

required significantly more powerful 

motors, leading to significantly higher 

energy consumption. This way, we simply 

achieve better results with less power,” 

explains Jens Steller, interim plant manager. 

“We opted for two blowers from 

the outset in case one of them fails. We 

absolutely cannot afford that. The blowers 

must always be running; otherwise, 

we risk excessive gas loss via the flare 

in the event of a failure.” In the biogas 

upgrading area, two additional compact 

Continental Industrie blowers of 

> 70 

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Fig. 3 shows a 6-stage blower from Continental Industrie GmbH that has been specially designed for 

CO 2 processing at the Friesoythe site. 



 

Visit Us: 

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09.–11.12.25 

Nürnberg, Germany 

Hall 9, Booth C38 

NETZSCH Pumpen & Systeme GmbH 

www.pumps-systems.netzsch.com


Fig. 4 shows the redundant recirculation blower from Continental Industrie GmbH, which 

extracts the methane-rich residual gas and feeds it back into the inlet of the PSA system. 

This prevents methane loss and makes it an efficient component of the system. 

 


type 051A.04 support recirculation. 

These blowers ensure that incompletely 

purified gas is fed back into 

the process, which is an essential 

measure for preventing methane slip 

and optimizing the process. 

A notable feature of the large 

plant is the CO 2 processing system. 

Rather than allowing carbon dioxide 

to escape unused, it is either liquefied 

directly on site or processed 

into dry ice. For this purpose, a sixstage 

Continental Industrie blower of 

type 077A1 is used as a pre-booster 

blower. It increases the pressure of 

the CO 2 from atmospheric level to 

1 bar(g), thus optimizing the efficiency 

of the downstream compressors. 

7/24: Biology works tirelessly 

“The plant currently comprises 12 

fermenters, four post-fermenters 

and four fermentation tanks – a total 

of 20 containers. In the final expansion 

stage, there will be 40 containers 

organized in ten rows of three 

fermenters, each with one post-fermenter 

– essentially ten biogas plants 

in one,” says project manager Niklas 

Hense. Nordfuel already produces 

3,500 to 3,700 Nm³ of biomethane 

per hour. Once the final expansion 

is complete, capacity will double to 

7,500 Nm³/h. 

“Two 20,000 m³ gas bubbles are 

available for buffer storage, guaranteeing 

a constant feed into the grid. 

An emergency gas flare is only used 

in extreme cases,” says Hense. “After 

all, production cannot be stopped 

because biological processes never 

take a break.” 

Even the processing of fermentation 

residues sets standards: after 

biomethane production, a usable end 

product remains that can be put to 

further use. Whether it is dried, processed 

into pellets or used as fertilizer, 

NordFuel makes optimum 

use of the entire material flow for 

all areas of application — a feature 

that is already unique in Europe. All 

processes comply with the EC Water 

Framework Directive and Nitrates 

Directive. 

A role model for future projects 

The 13.5-hectare plant is an example 

of an efficient, sustainable and wellthought-out 

concept. “We take the 

circular economy to its logical conclusion,” 

says Andrea Schneider. “Every 

component has its place and every 

resource is used.” 

Niklas Hense views the technology 

as a milestone, stating that “the 

combination of intelligent logistics, 

efficient biogas processing, and the 

resource-efficient utilization of fermentation 

residues sets new standards 

for the industry.” 

Continental Industrie’s blowers 

were put into operation in 2024. They 

play a central role in Nordfuel's stateof-the-art 

biogas processing. 

Fig. 5: View of the roofs of the fermenters at NordFuel (from left: Niklas Hense and Tobias Boeckh). 

 


Continental Industrie GmbH 

Gebläse- & Exhaustorentechnik 

Clemens-August-Platz 7 

41542 Dormagen, Germany 

Tel: +49 (0)2133 2598 30 

www.continental-industrie.de 



CO 2 Liquefaction – 

Sustainability through modern gas technology 

Envithan plant in Priborn featuring a BAUER CNK 420 screw compressor. 

 

All images: BAUER KOMPRESSOREN 

As environmental pressures rise 

and climate change advances, the 

responsible handling of carbon 

dioxide (CO 2 ) is becoming increasingly 

vital. CO 2 is generated as a 

by-product in many industrial processes 

and is often released unused 

into the atmosphere – with damaging 

consequences for the climate. 

Liquefying CO 2 offers an effective 

and sustainable solution: instead of 

being released into the air, the gas is 

captured, purified, compressed, and 

converted into liquid form. While 

still liquefied, CO 2 can be stored, 

transported, and put to practical 

use across multiple industries – 

such as beverage production. Recycling 

CO 2 via this approach helps 

reduce emissions consider ably and 

plays a key role in achieving global 

climate targets. Because the CO 2 

arises as a by-product of biogas 

production, the process delivers a 

double sustainability benefit within 

biogas generation itself. 

The CO 2 liquefaction process begins 

with collecting and pre-purifying 

Fig. 1: Envithan plant in Priborn in containerised design with BAUER CNK 420 screw compressor 

the raw gas, which typically contains 

impurities such as moisture, 

sulphur compounds, and other 

trace gases. The first process stage 

involves drying and purifying the 

gas to ensure the subsequent plant 

equipment will run reliably. It is then 

mechani cally compressed using 

high-performance screw compressors 

– such as those produced by 

BAUER KOMPRESSOREN. During this 

stage, the CO 2 is compressed to high 

pressure (typically between 10 and 

20 bar), a pre requisite for transforming 

it into liquid form. After compression, 

the gas is gradually cooled to 

temperatures below its boiling point. 

In specially designed condensation 

systems, the CO 2 is then liquefied 

under controlled conditions. The 

resulting liquid CO 2 can be stored 

in cryogenic tanks and supplied for 

industrial use. As well as being highly 

efficient, this technological process 

also marks a major step towards a 

circular economy and sustainable 

resource management. 

BAUER screw solutions – systematic 

climate protection 

As a premium manufacturer that has 

pioneered medium- and high-pressure 

gas compression with nearly 

80 years of global experience, 

BAUER KOMPRESSOREN leverages 

tailor-made, turnkey systems from 

a single source to provide the cutting-edge 

technology required. As an 

ISO 14001-certified company committed 

to sustainability, nothing is 

more important for BAUER than 

actively promoting climate protection 

and energy-transition goals. 

BAUER compressor systems are 

typically custom-engineered to suit 

the specific application. Their modular 

design allows for quick, straightforward 

installation and seamless 

integration into existing infrastructure. 

Depending on requirements, 

systems are available in variants 

offering low, medium, or high daily 

throughput. For biogas upgrading 


15


Fig. 2: CNK 420 system in closed design for outdoor use with cooler 

using the membrane process, in both open versions for indoor use 

screw compressors are required to 

generate the pressure necessary for 

and closed, weatherproof versions 

for outdoor installation. 

gas separation. 

The membrane process offers 

a streamlined way to refine biogas, 

CO 2 gas liquefaction: focusing on 

efficiency and performance 

separating carbon dioxide (CO 2 ) 

from methane (CH 4 ) to upgrade the 

gas to natural-gas quality. It employs 

semi-permeable membranes whose 

specific properties allow different 

gases to permeate at different rates. 

CO 2 diffuses through the membrane 

more rapidly and can thus be separated 

Recovering CO 2 as part of gas processing 

technology is now a tried 

and tested process. As a pioneering 

solution in the modern gas industry. 

BAUER’s purpose-built systems are 

an outstanding example of innovation 

and efficiency. This particularly 

effectively. 

BAUER KOMPRESSOREN offers 

wide-ranging air- and water-cooled 

complete screw-compressor systems 

to cater to this process, covering 

delivery rates from 10 m³/h up 

to 4,000 m³/h. With drive powers 

from 10 to 680 kW, the compressors 

achieve final pressures between 7 

and 20 bar (g). Their flexible configurations 

and numerous options allow 

them to meet the specific requirements 

of modern facilities. Complete 

systems are available with various 

configuration options, such as heat 

recovery. This feature allows the heat 

generated during the compression 

process to be used efficiently. This 

lowers operating costs and improves 

the plant's overall energy efficiency. 

Complete systems can also be supplied 

with or without a control cabinet 

as required. This allows for flexible 

integration into existing control systems 

or the creation of stand-alone 

control setups. Systems are available Fig. 3: CNK 420 system in open configuration 

applies to the CNK 420 system, which 

impresses not only through its technical 

specifications, but also its versatility 

and performance. 

The CNK 420 operates under 

optimal conditions with a suction 

pressure of 84 mbar(g) and a final 

pressure of 10 bar(g). These parameters 

are critical for efficient gas 

processing and ensure consistent 

biomethane quality. Delivering an 

impressive capacity of 1,580 m³/h, 

it ranks among the most powerful 

systems of its kind. Its design also 

allows for a maximum output of up 

to 1,800 m³/h, providing the flexibility 

to meet changing market demands. 

Overall, CO 2 recovery within gas-processing 

technology represents a 

major step towards a sustainable 

and high-performance energy supply 

that successfully unites economic 

efficiency with environmental 

responsibility. 

BAUER KOMPRESSOREN GmbH 

Munich, Germany 

www.bauer-kompressoren.de 



Wire mesh as a key to cost reduction 

in hydrogen production 

Innovative Porous Transport Layer (PTL) for scalable electrolyzer stacks 

Lars Wegner and Bentja Witte 

HyVentus, the reference stack for electrolyzers Image: Referenzfabrik.H 2 

Hydrogen: an energy carrier 

with challenges 

Hydrogen is considered a key technology 

in energy transition. As a storable 

energy carrier derived from 

renewable sources, it supports the 

decarbonization of energy-intensive 

industries and the development of 

cross-sector energy systems. However, 

its economic breakthrough 

depends largely on one factor: cost. 

Currently, hydrogen production via 

electrolysis is still significantly more 

expensive than fossil alternatives. In 

Germany, for example, the production 

cost of one kilogram of green 

hydrogen exceeds €7.50 (as of June 

2025, R1), far above the target of 1.00 

US dollar set by the U.S. Department 

of Energy (DOE) as a benchmark for 

a competitive hydrogen economy 

(R2; R3). 

Achieving this ambitious goal for cost reduction lies in the stack— 

requires technological innovation the heart of the electrolyzer. This is 

and industrial scaling. One example: where the highest capital expenditures 

In PEM electrolysis (Proton Exchange 

(CAPEX) occur. To reduce these 

Membrane), the greatest potential costs, we need: 

Fig. 1: Cost reduction diagram for PEM electrolyzers Image: based on Referenzfabrik.H 2 


17


• Cost-efficient materials and manufacturing 

technologies 

• Scalable designs for mass production 

(“Design to Assembly”) 

• High-performance components 

that enhance efficiency and 

durability 

Challenges in the stack – The role of 

the Porous Transport Layer (PTL) 

To improve the economic viability of 

electrolysis, the stack becomes the 

central focus. It consists of various 

components with different functions— 

including the Porous Transport Layer 

(PTL), which plays a crucial role in the 

efficiency of the Membrane Electrode 

Assembly (MEA). Positioned between 

the bipolar plate and the cata lystcoated 

membrane (CCM), the PTL fulfills 

two essential tasks: 

• Delivering purified water to 

the CCM 

• Removing the resulting gas 

bubbles 

To ensure these processes work 

reliably, the PTL must offer high 

electrical conductivity, porosity, and 

corrosion resistance—even under 

extreme operating conditions—to 

protect the CCM. The material and 

structure of the PTL significantly 

influence the efficiency, lifetime, and 

invest cost of an electrolyzer. 

Until this date, titanium fiber 

fleece or powder-sintered materials 

have often been used as PTL. While 

offering high porosity, they also present 

drawbacks: 

• Inhomogeneous pore distribution: 

Porosity varies across the surface 

• Chaotic structure: Gas bubbles or 

droplets may become trapped, 

reducing efficiency 

The solution – 3D wire mesh as PTL 

A technological breakthrough with 

high industrial potential is the use 

of three-dimensional titanium wire 

mesh. The mesh structure is based 

on the RPD-HIFLO series—a specially 

developed high-performance filter 

mesh known for its precisely defined 

pore geometry and high flow capacity 

for liquids and gases. Unlike traditional 

square meshes or braids, this mesh 

features a three-dimensional architecture 

that offers both technological 

superiority and economic advantages: 

• Defined pore geometry: 

Prevents gas bubble entrapment 

and enables rapid removal 

• Comparatively smooth surface: 

Ensures reliable membrane contact 

without mechanical damage 

• High internal porosity: Supports 

efficient gas diffusion and water 

distribution 

• Roll-to-roll processing: Enables 

automated stack assembly 

• Calibratable thickness: Allows 

flexible integration into various 

stack designs 

• Cost advantage: Up to 70% 

cheaper than conventional substitutes 

due to the elimination of 

thermal sintering 

• Higher efficiency: Improved 

electro chemical performance 

compared to fleece or powdersintered 

PTLs 

The material used is Titanium 

Grade 1 (Material No. 3.7025)—a corrosion-resistant, 

high-purity material 

with excellent electrochemical stability. 

Typical PTL thickness ranges from 

300 to 700 µm, depending on wire 

diameter and desired porosity. 

Using wire mesh as PTL contributes 

to cost reduction in hydrogen 

production on multiple levels. 

Thanks to industrial weaving processes, 

it can be efficiently manufactured 

in large quantities, significantly 

enhancing scalability. 

Fig. 2: The MINIMESH ® RPD HIFLO-S filter braid as an example of 3D wire mesh 

Image: Haver & Boecker 


FILTECH 

June 30 – July 02, 2026 

Cologne – Germany 

The Filtration Event 

www.Filtech.de 

Platform 

for your 

Fig. 3: Structure of the HyVentus PEM stack 

Image: based on Fraunhofer IWU 

success 

Practical insight: HyVentus – 

Scalable stack development 

in practice 

A concrete development project that 

exemplifies how technological innovations 

can be translated into scalable industrial 

applications is the development of 

the HyVentus electrolyzer stack—initiated 

by the Referenzfabrik.H 2 at Fraunhofer 

IWU. The goal is to develop a cost-effective 

and scalable electrolyzer stack designed 

specifi cally for mass production. 

To achieve this, a cross-industry consortium 

was formed, now com prising 

over 30 partners from industry and 

research—including Fraunhofer IWU, 

Linamar, Aumann, Fraunhofer ENAS, 

Horiba, and HAVER & BOECKER. Together, 

they analyze all stack components and 

develop new solutions suitable for industrial 

series production—from the bipolar 

plate to the CCM and GDL (Gas Diffusion 

Layer), to the current distributor plate 

and PTL. 

The PTL showcases the potential 

of innovative materials like wire mesh: 

Through roll-to-roll manufacturing, the 

mesh can be ideally combined with other 

scalable processes—such as the embossing 

technique used in the project for producing 

bipolar plates. This techno logy 

enables precise structuring of metallic 

plates with high production speed and 

reduced unit costs. 

The principle of “Design for Manufacturing 

& Assembly” runs throughout the 

project: Components are optimized not 

only functionally but also for manufacturability. 

The result is a stack that is both 

high-performing and economically producible—a 

crucial step toward hydrogen 

production at 1.00 US dollar per kilogram. 

The Authors: 

Lars Wegner (MBA & Eng.) 

Business Development Manager 

E-Mail: L.Wegner@haverboecker.com 

Bentja Witte 

Marketing 

HAVER & BOECKER OHG 

www.haverboecker.com 

Refences 

R1: www.oeko.de/fileadmin/ 

oekodoc/Matthes_Brauer- 

Wasserstoff-Erzeugungskosten.pdf 

R2: www.utilitydive.com/news/ 

doe-clean-hydrogen-fuel-cell- 

program-plan/715606/ 

R3: https://power-to-x.com/us-en 

ergieministerin-will-mit-hydro 

gen-shot-die-kosten-fuer-sauber 

en-wasserstoff-auf-1-dollar-pro-kilo 

gramm-senken/ 


600+ Exhibitors 

Delivers 

solutions for 

current 

and future 

challenges 

Your Contact: Suzanne Abetz 

E-mail: info@filtech.de 

Phone: +49 (0)2132 93 57 60


The safe way to transport hydrogen – 

with the MEGC container 

Felix Brühl and Benjamin Lemke 

transport, reduces logistical risks, 

and increases efficiency throughout 

the entire supply chain. 

Multimodal use with 

high transport capacity 

The MEGC container is designed as a standard 40" container that can be flexibly deployed 

across various transport environments – whether by freight train, ship, or truck. 

 

Image: Hexagon Purus 

Endress+Hauser, together with four 

project partners, is developing an 

innovative MEGC (Multiple-Element 

Gas Container) within a publicly 

funded project consortium. This 

cutting-edge container sets new 

standards for the safe and efficient 

transport of hydrogen. Designed 

as an integrated system, it combines 

state-of-the-art measurement 

and automation technology with 

advanced storage and materials 

engineering – creating a key foundation 

for the large-scale rollout of 

hydrogen. 

Hydrogen is considered a strategically 

important energy carrier for 

Fig. 1: Endress+Hauser is developing an 

MEGC container within a publicly funded 

project consortium that sets new standards 

for the safe and efficient transport of 

hydrogen. 

 

Image: Endress+Hauser 

the transformation of industry and 

mobility. However, its widespread 

use has so far been hindered by significant 

transport challenges. In the 

absence of a robust pipeline network, 

distribution currently takes place 

mainly by truck, rail, or ship. These 

transport modes place high demands 

on pressure storage, safety, and 

handling. This is precisely where the 

MEGC container comes in: it has been 

developed by a strong consortium 

comprising Endress+Hauser, a global 

leader in measurement and automation 

technology; Hexagon Purus, 

a specialist in high-pressure hydrogen 

storage systems; DB Cargo BTT, a 

leading provider of hazardous goods 

logistics for rail freight; Infraserv 

Höchst, operator of the Höchst Industrial 

Park with extensive hydrogen 

expertise; and the Fraunhofer IML, 

renowned for its research in material 

flow and logistics. The collaborative 

project is funded by the German 

Federal Ministry for Economic Affairs 

and Energy. 

By combining automation expertise 

with advanced material and 

storage technology, the container 

enables safe, multimodal hydrogen 

The MEGC container is built as a 

40’ PW container that can be flexibly 

deployed across various transport 

environments – whether by freight 

train, ship, or truck. With a capacity 

of up to 1,250 kilograms of hydrogen 

at 500 bar pressure, it offers a high 

transport volume while meeting the 

most stringent safety standards. A 

key feature is the integrated remote 

monitoring system: it continuously 

records data on pressure, temperature, 

and the container’s location, 

securely documents it, and transmits 

it in real time. This gives operators 

full visibility of their entire fleet at all 

times, enabling more efficient transport 

planning and management. 

Operating modes for stationary 

and mobile applications 

In normal operation, the container 

functions in two modes. In stationary 

mode, loading and unloading can 

be controlled using calculated filling 

curves, and both pressure- and 

temperature-controlled processes 

are possible. All operations are fully 

logged – both locally and remotely – 

and data relevant for legal metrology 

and billing is exchanged automatically. 

Control and communication 

can be wireless (WLAN with Profi- 

Safe) and, thanks to open protocols, 

are compatible with both proprietary 

and third-party operator panels. 

In addition, a manual mode is available 

for emergency situations, allowing 

pneumatic operation by hand. 

For precise hydrogen measurement, 

a certified metering system is integrated, 

recording both intake and 

discharge. This enables accurate, 

audit-proof billing between producers 



and consumers. Moreover, the container 

performs filling and emptying 

autonomously: through automated 

communication with counterpart 

stations via open interfaces, the logistics 

process is executed reliably and 

efficiently. 

In mobile mode – during transport 

by rail, truck, or inland vessel – the 

container records and transmits all 

safety- and logistics-relevant operational 

data, including pressure, temperature, 

fill level, and real-time GPS 

position via cellular communication. 

Boosting efficiency through 

automated maintenance processes 

In hydrogen transport, every hour 

that a container is out of operation 

matters. Mandatory maintenance 

and safety inspections are essential 

but time-consuming, reducing container 

availability. 

This is precisely where 

Endress+Hauser’s Heartbeat Technology 

makes a difference. In a dedicated 

maintenance mode, required 

SIL proof tests can be carried out 

automatically, contact-free, and via 

Bluetooth – without dismantling any 

components. For example, inspection 

time for measuring devices is 

reduced from around 35 minutes 

to just 2 minutes and 40 seconds, 

a time saving of more than 90 percent. 

At the same time, error risk 

decreases, safety increases, and personnel 

are significantly relieved. Most 

importantly, the container is ready 

for transport much sooner – a measurable 

gain in reliability and performance 

across the entire hydrogen 

logistics chain. 

Networking and integration into 

hydrogen infrastructures 

In day-to-day operations, success 

depends not only on safe transport 

and minimal downtime but also on 

precise distribution: Where is hydrogen 

currently needed? Where is it 

available? How can it be transported 

quickly and efficiently? Thanks to 

open interfaces, MEGC containers 

can be integrated into over arching 

hydrogen information networks. 

These networks continuously collect, 

document, and share data on 

supply and demand, providing full 

transparency. Based on this data, 

operators can manage distribution 

in a targeted, flexible, and efficient 

way. This creates an essential building 

block for establishing a reliable 

supply chain and a functioning hydrogen 

infrastructure. 

The solution combines modern 

monitoring, flexible operating modes, 

optimized maintenance processes, 

and seamless connectivity with logistics 

platforms. Altogether, the smart 

MEGC container becomes a key 

enabler for both short- and longterm 

hydrogen supply security and a 

Fig. 2: The MEGC container offers a unique 

combination of monitoring, versatile operating 

modes, optimized maintenance processes, 

and seamless connectivity with 

logistics platforms. Image: Hexagon Purus 

cornerstone of a successful hydrogen 

strategy. 

The Authors: 

Felix Brühl 

Business Development Manager 

(Sales Marketing) 

Benjamin Lemke 

Expert System Architecture at 

Endress+Hauser 

HIGH-PRESSURE TECHNOLOGY 

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Sustainable materials: Durable, environmentally friendly, low 

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21


Innovative warehouse shuttle system with regenerative energy 

Up and away with Bergzeit 

Andrea Balser 

From the attic to the 

high-bay warehouse 

The MOVIDRIVE MDR90B sinusoidal regenerative power supply (center of image, gray) is 

designed for 50 kW energy supply and recovery with a maximum peak of 2.5 times that. Just 

like the MOVIDRIVE ® modular frequency inverter with four axes (to the right of it), it is part of 

the MOVIC ® modular automation system. 

Image: SEW 

Seven aisles accommodating 54 000 

storage spaces for items of clothing 

and equipment for mountain sports. 

Bergzeit GmbH started up its highbay 

warehouse and downstream 

logistics in 2022, and has been serving 

its customers even faster and 

even more sustainably ever since. 

The new warehouse shuttle system 

is fitted with regenerative drive 

technology from SEW-Eurodrive. 

Bergzeit GmbH offers a wide range of 

products covering all kinds of mountain 

sports – be it hiking, climbing, 

mountaineering, ski tours, or biking. 

The company is based in Otterfing, 

Upper Bavaria, some 30 kilometers 

south of Munich. The mountain 

sports equipment provider was 

founded in 1999 as a classic startup 

based out of someone’s attic. Initially, 

founder Klaus Lehner provided touring 

information on the Internet, and 

came into contact with a lot of people 

via the touring portal. This gave rise 

to a growing number of queries 

about equipment. 

The foundations for Internet 

sales were laid with bike computers. 

The “Bergzeit” online shop 

went live in 2001. The company 

grew rapidly, opening branches 

in Grosshartpenning near Holzkirchen 

and Gmund am Tegernsee 

in 2003 and 2010. The new Bergzeit 

headquarters, with logistics and an 

adminis trative building, was opened 

in Otterfing near Holzkirchen in 2017. 

For the first few years, shipping processes 

were entirely manual. Since 

capacity limits were soon reached, 

the company’s management decided 

to build an automated warehouse 

shuttle system in 2020. 

When the extension was complete, 

Bergzeit had a service provider install 

the shelving system. psb intralogistics 

GmbH then fitted the shuttle system. 

“In addition to ensuring efficient 

logistics processes, we wanted the 

warehouse shuttle system to be sustainable 

in energy terms, too,” says 

Holger Cecco-Stark, Head of Facility 

& ECO-Management at Bergzeit. One 

requirement was therefore the ability 

to feed the braking energy from the 

lifts back into the supply system. This 

was where SEW-Eurodrive drives 

with regenerative units came in. 

Since the new high-bay warehouse 

is an energy-intensive facility, a new 

transformer was also installed. The 

automated warehouse was finished 

in 2022. It features 54 000 storage 

spaces in seven identical aisles, with 

eight shuttles operating in each. The 

shuttles can move freely between 

levels. “Items are stacked three-deep 

in the aisles,” explains Cecco-Stark. 

“Wherever a shuttle stops, it can 

therefore serve six storage spaces.” 

Hoists with powerful acceleration 

In this high-bay warehouse, two 

hoists are installed at the front of 

each aisle, and two more in the 

middle of the aisle. At the customer’s 

Fig. 1: This building houses the administrative offices, with the Bergzeit logistics center in two 

halls behind it. 

Image: Bergzeit 



request, sinusoidal regenerative 

power supply modules were used. 

Klaus Kröner, applications engineer 

for regenerative power supply units 

at SEW-Eurodrive, supported psb 

right from the first field tests of these 

units. Based in Pirmasens, the system 

manufacturer is a long-standing 

partner of SEW-Eurodrive, and was 

one of the first users of these regenerative 

power supply units. Together 

with a control technician from psb, 

the SEW-Eurodrive service team optimized 

the control of the sinusoidal 

regenerative power supply units and 

implemented energy meters – digital 

interfaces that measure the current 

motor or regenerative energy 

flow. The regenerative power supply 

units are fitted with IGBTs operating 

at 12 kHz. A filter choke as a low pass 

prevents the 12 kHz clock frequency 

getting into the supply system. When 

there is no travel order for the lifts, the 

regenerative power supply is blocked 

after one minute to prevent idling 

losses. The MOVIDRIVE ® MDR90B 

sinusoidal regenerative power supply 

is designed for 50 kW energy supply 

and recovery, with peak power 

2.5 times that. Just like the frequency 

inverters of the MOVIDRIVE ® modular 

series, this supply unit is part of the 

MOVIC ® modular automation system. 

Fig. 2: Transport crates are used for order picking on several conveyor lines in the new 

logistics hall. 

Image: SEW 

Fig. 3: At the order picking stations, the items of clothing and equipment are removed from 

containers, which are then returned to the warehouse. 

Image: SEW 

Sustainable power supply 

Bergzeit GmbH attaches great importance 

to environmentally friendly use 

of resources. As part of its strategic 

alignment, the company developed 

an energy concept that is established 

in almost every section of 

the company, and continues to be 

expanded. Since 2020, the company 

has opted for validation under 

the EU's Eco-Management and Audit 

Scheme (EMAS), which ensures that 

every environmental consideration – 

from energy consumption to waste 

and emissions – is taken into account 

transparently and in line with legal 

requirements. 

Bergzeit installed a photovoltaic 

system on the roof to supply 

current, opting for the maximum 

possible configuration to ensure 

future viability. “We currently produce 

around 550 000 kilowatt hours 

Fig. 4: Erectors adjust the packaging boxes to the actual fill-level. This helps conserve 

resources in onward transport. 

Image: SEW 

per year,” Cecco-Stark explains. “We 

are aiming to have eliminated fossil 

fuels completely at our site by 2030.” 

In terms of its vehicle fleet, too, the 

company has moved to a more sustainable 

approach. As Cecco-Stark 

says, “We started with our company 

cars, switching them from internal 

combustion engines to e-vehicles. 

We have now switched 99 percent 

of our cars, with the last one set to 

follow next year.” He goes on to say 

that one of the two logistics buses 

that supply the two branches is currently 

being replaced with an e-transporter. 

“The central incoming goods 

department is in Otterfing. If one of 

the branches needs a certain item, it 

is picked in Otterfing and transported 

to the branch,” he explains. Goods 

also move in the opposite direction. 

For example, goods from the upper 

price segment are displayed in the 

branches – after all, it’s no good if 

they are lying around invisible in the 

warehouse – but are also available 

to buy via the online shop. When a 

pro duct is sold online, it is brought 


23


Fig. 5: Four gearmotors operate in each 

aisle, two at the entrance and two in the 

middle. They are each fed by an inverter 

axis. 

Image: SEW 

back to the central warehouse and 

shipped from there. 

Clean energy at a low price 

The photovoltaic system produces 

up to 550 000 kWh of energy per 

year, and is certified under the Re gister 

of Guarantees of Origin (HKNR). 

As a result, Bergzeit GmbH is able to 

both generate and sell green energy. 

After covering on-site requirements, 

e. g. for the 20 in-house charging stations, 

the company feeds the remaining 

power – around 40 percent of 

the total yield – into the supply grid. 

“Initially, we offered the electricity to 

our staff at a preferential price via 

our partner EWS (Elektrizitätswerke 

Schönau). Our customers can now 

also benefit from this offer,” says 

Cecco-Stark. He believes autonomous 

regional energy networks are 

the future, as long as grid operators 

cooperate and there is the political 

will to remove bureaucratic obstacles. 

Sustainability influences 

purchasing decisions 

Cecco-Stark is a mountain sports 

enthusiast himself. The Alps sparked 

his interest when he was a child, and 

he spent many vacations there with 

his parents. While he was at university, 

he often went on weekend trips 

to the mountains. Around 12 years 

ago, he began working at Bergzeit 

GmbH and was able to combine business 

with pleasure. Thanks to his volunteer 

work as a countryside ranger, 

he was quick to recognize the beneficial 

symbiosis of mountain sport 

and closeness to nature. Around 

eight years ago, he worked with the 

new managing director at the time 

to develop an initial sustainability 

concept, and employed a sustainability 

manager. “We worked with her 

to continuously develop our strategy 

and targets, and for some customers 

this is a key factor in their decision to 

buy.” 

Remote working helps achieve 

sustainability targets 

Bergzeit produced its first climate 

assessment in 2019, and used this 

as a basis for setting ambitious targets 

in terms of cutting its carbon 

footprint. To this end, the company 

joined the Science Based Targets Initiative 

(SBTi). The company now has 

around 150 more employees than in 

2019. Of course, they have to get to 

work somehow. Bergzeit subsidizes 

50% of the cost of the Deutschlandticket 

(German subscription ticket 

for local public transport) to encourage 

staff to switch to public transport. 

Otterfing is convenient for the northsouth 

line of the local suburban railway. 

“However, depending on where 

you live, you might still need a car,” 

Cecco-Stark states. “This runs completely 

contrary to our sustainability 

goals,” he continues. He explains that, 

to counteract this, they have introduced 

measures such as free charging 

for electric vehicles. Some 25 

members of staff currently make use 

of this option and invest the money 

they save on fuel into a vehicle leasing 

contract. Another way the mountain 

sports equipment provider supports 

its employees is by being very open to 

remote working. Anyone whose job 

description allows it (primarily administrative 

staff) can work remotely. 

Bergzeit GmbH operates a working 

time model based on trust, and this 

works very well. Cecco-Stark reports 

that the company attaches great 

importance to personal organization, 

individual responsibility and self 

motivation. “That is also a development 

process.” He also explains that, 

as long as all the necessary work has 

been done, all members of staff have 

the option of taking a spur-of-the-moment 

trip into the great outdoors to 

enjoy fresh snow on a winter’s day. 

The Author: 

Fig. 6: Bergzeit GmbH switched to DHL’s GoGreen Plus service for shipping in 2024 

 

Image: Bergzeit 

Andrea Balser 

Trade Press Officer 

SEW-Eurodrive, Bruchsal, Germany 

Further information: 

www.sew-eurodrive.de/regenerativepower-supply 

Or video: youtu.be/N-mnuyf_ 

kso?si=eXBcqBwevTO4qm6t 



Green district heating for Giessen 

Sustainable heat supply via the PowerLahn project 

and three large-scale heat pumps from Johnson Controls 

Erik Joseph 

Sustainable heat from the Lahn: The powerful Sabroe DualPAC large heat pumps extract heat from the river water and feed it efficiently into 

the existing district heating network. 

Image: Johnson Controls 

District heating plays a central role 

in the heat transition. It can enable 

a sustainable heat supply – particularly 

through the targeted use of 

renewable energy and innovative 

technologies. Stadtwerke Giessen 

(SWG) is demonstrating what this 

can look like with its PowerLahn pilot 

project, which combines three largescale 

heat pumps from Johnson 

Controls, two combined heat and 

power (CHP) plants and a powerto-heat 

(P2H) system to create an 

innovative CHP system designed for 

maximum efficiency, flexibility and 

CO 2 reduction. Commissioning is 

planned for mid-2026. 

A key contributor to a successful 

and sustainable energy transition in 

heating is the use of already available 

energy sources with the shortest 

possible transport routes. In Giessen, 

the Lahn River offers a readily available, 

locally accessible heat source: 

its water supplies thermal energy 

directly to the urban area, which 

can be efficiently integrated into the 

existing district heating network. The 

innovative CHP plant harnesses the 

river’s potential and generates both 

thermal energy and electricity, earning 

the project its name, “Power 

Lahn”. 

Utilizing river water as 

a thermal energy source 

At the heart of the state-subsidized 

innovative CHP plant are three 

Sabroe DualPAC water/water heat 

pumps from Johnson Controls, which 

extract thermal energy from the Lahn 

river to feed it into the existing district 

heating network. Combined with two 

CHP units and a P2H system, which 

are also designed for maximum 

energy efficiency and CO 2 reduction, 

the large-scale heat pumps produce 

around 29,000 MWh of heat energy 

per year, which will supply around 

3,900 households in Giessen with 

emission-free heat in the future. 

To do this, river water is extracted, 

routed directly through the heat 

pump's evaporator and returned to 

the Lahn at a slightly lower temperature. 

Johnson Controls has designed 

its DualPAC large heat pumps with a 

heat output of up to 1,700 kW specifically 

for large-scale use in district 

heating systems: The state-of-theart 

machines combine the technologies 

of the ChillPAC chiller series 

and the HeatPAC heat pump series, 

which have already proven them 


25


Fig. 1: In the CHP system operated by Stadtwerke Gießen, large heat pumps take over the base 

load of district heating supply during the warmer summer months. Image: Johnson Controls 

selves many times over. They use 

a water-glycol mixture as the heat 

source. Maximum energy efficiency is 

ensured by their two-stage compression 

system, which does not use a 

performance-reducing intermediate 

heat exchanger, but instead a medium-pressure 

tank that reduces the 

amount of refrigerant required to just 

115 kilograms of ammonia (R717). 

The natural refrigerant is not subject 

to the F-gas Regulation and is therefore 

future-proof in the long term. 

With a COP (Coefficient of Performance) 

of 3.9, DualPAC large heat 

pumps offer high efficiency, resulting 

in low operating costs and minimal 

CO 2 emissions. For every kilowatt 

hour of electricity used, they generate 

more than twice as much heat. 

Furthermore, at seven meters long, 

three meters wide, 2.6 meters high 

and weighing around 17 tons, they 

are also extremely compact. 

PowerLahn project – an innovative 

CHP system with a bright future 

In SWG’s innovative CHP system, the 

three large-scale heat pumps take 

over the base load of the district heating 

supply during the warmer summer 

months. From April to October, 

the water in the River Lahn usually 

provides sufficiently high temperatures 

to enable this. A positive side 

effect is that the targeted cooling of 

the river water in the return flow also 

counteracts overheating and thus 

even helps to protect sensitive organisms 

in the river. 

During the heating period, the two 

innovative CHP units in the system 

supplement the supply. They are primarily 

used when the flow temperatures 

are low and the heat pumps are 

therefore less efficient. The CHP units 

generate around 50,000 MWh of heat 

and around 47,000 MWh of electricity 

per year, achieving an overall efficiency 

of 95 %. They ensure a reliable 

heat supply even when outside temperatures 

are low. 

The P2H system, which uses surplus 

energy from renewable sources 

and converts it into heat, is also an 

essential part of the innovative CHP 

system. Its work further contributes 

to the decarbonization of the heating 

grid, but also serves to stabilize 

the electricity grid – especially when 

there is a high feed-in of wind and 

solar power. This enables a flexible 

response to fluctuations in the electricity 

grid. 

The two CHP units and the P2H 

module are located at the municipal 

utilities on the site of the CHP plant 

and will replace the older gas turbines 

at HKW Gießen GmbH in the 

future. With its innovative CHP, SWG 

will save over 7,700 tons of CO 2 per 

year in the future and make a significant 

contribution to climate change 

mitigation. 

A model for sustainable 

urban heating and potential savings 

With the PowerLahn project, SWG 

and Johnson Controls are demonstrating 

how a sustainable solution 

for municipal heat supply could ideally 

be designed. The water from the 

River Lahn, which would flow, unused, 

around the clock without the innovative 

CHP system, is being tapped as a 

renewable energy source using stateof-the-art 

technology. This helps to 

significantly increase the efficiency, 

cost-effectiveness and security of 

supply of the district heating network. 

Compared to conventional gas 

heating systems, the generation costs 

are significantly lower. 

The Giessen municipal utility’s 

pilot project marks another important 

step towards heat transformation. 

It proves that local environmental 

heat can be efficiently integrated into 

existing infrastructures to generate 

ecological and economic benefits – 

and can therefore serve as a model 

for other cities. 

A role model for the whole 

of Europe 

Projects like PowerLahn are fundamental 

for the heat transition in 

Europe. Critical industries and facilities 

lose large amounts of valuable 

heat energy every day because 

it either escapes unused from processes 

or is not tapped from natural 

sources such as air, soil or water. 

However, cities and municipal utilities 

such as SWG, energy suppliers, and 

industrial companies are increasingly 

turning to heat pump solutions to utilize 

such energy sources. They benefit 

from significantly lower operating 

costs and CO 2 emissions – while also 

making a positive contribution to the 

environment. 

For example, a hospital that 

used a geothermal heat pump to 

draw heat from a tunnel 200 meters 

below ground was able to reduce 

its energy costs by 30% – and reliably 

cover 80 % of its heating requirements. 

In Denmark, Aalborg Hospital 

has achieved near climate neutrality: 

its CO 2 emissions have been reduced 

by up to 90 % and its energy costs by 



Fig. 2: Johnson Controls is a pioneer in heat pump solutions and offers a comprehensive portfolio for commercial, institutional, and 

industrial applications. 

Image: Johnson Controls 

80 %. Meanwhile, Hounslow Council 

in the UK has invested in converting 

60 schools and public buildings from 

gas heating systems to air source heat 

pumps and is now saving over 50% 

on energy costs and CO 2 emissions. 

Heat pumps also offer great potential 

for industry: a leading Spanish food 

manufacturer saves 1.5 million euros 

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Johnson Controls 

At Johnson Controls (NYSE:JCI), we 

transform the environments where 

people live, work, learn and play. As 

the global leader in smart, healthy 

and sustainable buildings, our mission 

is to reimagine the performance 

of buildings to serve people, places 

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Building on a proud history of 

140 years of innovation, we deliver 

the blueprint of the future for industries 

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offering. 

Today, Johnson Controls offers 

the world’s largest portfolio of building 

technology and software as well 

as service solutions from some of the 

most trusted names in the industry. 

For more information, visit 

www.johnsoncontrols.com 

and follow us at @johnsoncontrols 

on social platforms. 

and around 2,000 tons of CO 2 annually, 

which is equivalent to the emissions 

of around 400 households. 

a comprehensive portfolio for commercial, 

institutional, and industrial 

applications. The company's 

machines can already utilize all types 

of natural energy sources, such as 

sea water, river water, lake water, 

wastewater, solar energy, biomass, 

and geothermal energy. The integration 

of unavoidable waste heat from 

industrial processes and data centers 

is already feasible and equally futureproof. 

With heat pumps designed for 

refrigerants with low or very low 

global warming potential, Johnson 

Controls is also playing a leading role 

in the transition to climate-friendly 

refrigerants. Thanks to machines 

from this global company, customers 

were able to reduce their operating 

costs by an average of 53 % and CO 2 

emissions by 60 % in 2024 compared 

to conventional gas heating systems. 

In conclusion 

The energy transformation in heating 

is one of the top issues in the energy 

industry for achieving municipal and 

private sector decarbonization targets. 

According to the Environmental 

Protection Agency (EPA), an estimated 

5 % of the world's daily fuel energy 

consumption is used to heat water. 

In addition, around 25 % of primary 

energy in Western European countries 

is used for cooling and heating 

applications. 

As natural resources remain 

under pressure and energy bills will 

continue to rise in the future, it is 

essential to look for new, environmentally 

friendly solutions. Whether 

in the air, water, ground or processes: 

Unused thermal energy 

can be found everywhere, and heat 

pump systems tap into this energy 

and make it usable via district heating 

networks. They improve operating 

results, ensure the avail ability 

and efficiency of critical infrastructures 

and drive investment 

into innovation, leading to greater 

competitiveness. 

Regardless of the source, largescale 

heat pumps can be operated 

locally. This increases regional value 

creation and supports the energy 

independence of communities and 

cities. Heat pumps are therefore 

becoming indispensable. They are 

essential and a key technology for the 

energy turnaround in Europe. 

Heat pumps in action 

The project in Giessen 

Whether global industrial and manufacturing 

companies, hospitals, 

cities and municipalities, or energy 

suppliers: successes like these are 

based on heat pumps developed and 

built by Johnson Controls in Europe. 

They offer Europe the opportunity 

to become a global leader in energy 

technology while strengthening its 

traditional core industries. 

Johnson Controls is a pioneer 

in heat pump solutions and offers 

Autor: 

Erik Joseph 

Sales Manager HVACR Energy 

Industrial and Large Heat Pumps 

Johnson Controls 

Further information can be found at 

www.johnsoncontrols.com 

Component l 

Sabroe DualPAC heat pumps 

• Output: 3 x 1,774 kWth 

• Guaranteed running time: 

April to October 

• Emission-free heat extraction: 

up to 29,000 MWh 

• Homes supplied: around 3,900 

• CO 2 savings (compared to a gas 

boiler): 7,767 tCO 2 /a 

Components ll + lll 

CHP units and P2H module 

• Thermal output: 2 x 4,726 kWth 

• Electrical output: 2 x 4,507 kWel 

• Secured running time: 

September to April 

• Heat generation: 49,995 MWh 

• Electricity generation: 46,934 MWh 

• Homes supplied (heat): around 6,800 

• Average households (electricity): 

around 21,300 

• CO 2 savings (compared to turbine 

system): 2,736t CO 2 /a 

“The biggest challenge for a climatefriendly 

district heating supply is the 

efficient integration of renewable energies 

into existing systems. With PowerLahn, we 

are using a local, renewable energy source 

and combining it with an innovative heat 

pump technology, combined heat and 

power generation, and power-to-heat. 

This model shows how sustainable heat 

supply can work in practice.” 

Matthias Funk 

Technical Director 

of Stadtwerke Giessen 



Intelligent AI-based energy systems from Greenflash 

On the way to becoming energy self-sufficient 

Hendrik Knese 

For the intelligent AI-based energy system installed in Twist, Greenflash combined the three PV installations of Giga Coating and System 

Trailers into one system with a total output of more than 2 MWp. 

Image: Greenflash GmbH 

Essen-based company Greenflash, 

in collaboration with STABL Energy, 

has implemented an intelligent 

energy system for their joint customer, 

the duo Giga Coating and 

System Trailers in the Emsland 

region. The combination of photovoltaics 

and energy storage using 

recycled electric car batteries is controlled 

by the new AI-based software 

Greencore AI from Greenflash. 

This offers advantages to energyintensive 

industrial enterprises such 

as Giga Coating and System Trailers 

that were hardly viable on this scale 

in the past. 

The energy transition has meanwhile 

arrived in industry, albeit with varying 

degrees of pressure for the different 

sectors to take action. However, 

issues such as rising energy prices 

and the necessity of orientation 

toward renewable energies are here 

to stay. Companies who fail to face 

these challenges and find answers 

and solutions in the short-term risk 

nothing less than economic ruin. 

Solar power yes, 

but only if it is intelligent! 

Many companies have already 

decided to install systems that allow 

them to cover at least part of their 

energy demand self-sufficiently, for 

example with photovoltaics. In principle, 

this is a good first step, but 

for the experts at Greenflash, the 

PV installation on the roof alone is 

inadequate. “Without intelligent control 

and a comprehensive concept, a 

simple PV installation not only leaves 

huge potential unused, but also costs 

the owner money,” explains Lennart 

Oklitz, Project Manager at Greenflash. 

“That happens on days when there is 

an oversupply of electricity at certain 

times. The feeding of self-generated, 

‘excess’ power to the grid costs up to 

1,000 euros or more in just one day.” 

More about this below. 

For Giga Coating GmbH and the 

vehicle manufacturer System Trailers 

just next door – the two companies 

are affiliated, with headquarters in 

Twist, near the city of Meppen in the 

Emsland region – the joint management 

decided to use an intelligent 

energy system such as that 

developed and implemented by 

Greenflash. Giga Coating is the site of 

Europe’s most modern surface coating 

plant for cathodic dip coating and 

powder coating, which is also utilized 

for fully automated coating of large 

workpieces for use in industry. The 

high power consumption of the stoving 

ovens forced the company to find 

alternatives to fossil fuels. 

Energy requirements at System 

Trailers are likewise high, in this case 


29


explained by Nam Truong, CEO and 

co-founder of the company with headquarters 

in Munich and a branch in 

Berlin: “While the market for storage 

solutions generally relies on long battery 

chains and high-voltage batteries, 

our architecture with battery modules 

provides for increased durability, reliability, 

and efficiency. This even allows 

the use of recycled batteries from electric 

cars, with no compromises in performance 

and service life. This is an 

important aspect with a view toward 

resource efficiency and recycling.” 

Modular concept with 

multi-level inverter 

Fig. 1: Acceptance of the energy storage system for Giga Coating and System Trailers by 

Greenflash and STABL in June 2025 in Twist, Emsland – left, Lennart Oklitz, Technical Project 

Manager at Greenflash; right: Markus Weiss, Project Manager at STABL. 

 


for the welding robots used for the 

timely production of large quantities 

of trailers and semi-trailers in a wide 

variety of versions. In 2022, the two 

companies contacted Greenflash 

with the request to develop a 

sustainable solution for the power 

supply. 

“There are several reasons why Giga 

Coating and System Trailers are 

special customers for us,” explains 

Lennart Oklitz. “For example, we combined 

the two connecting points for 

the power grid to create a single system. 

The PV systems of both companies 

were initially installed separately, 

with 390 kWp at System Trailers and 

749 kWp at Giga Coating. They were 

likewise combined in this process.” 

Another simultaneously installed PV 

system with 1.2 MWp was certified 

and commissioned by Greenflash. 

Oklitz continues: “Since we are the 

general contractor for this project, 

we were able to set the course early 

on for a comprehensive, intelligent 

solution, including connection to the 

energy exchange. Another important 

milestone was the seamless integration 

of a power storage system for 

the solar power generated. This system 

was built by our partner STABL 

Energy, delivered in a 20-foot container 

in June 2025, and commissioned 

jointly.” 

The special feature of the STABL 

solution is the modular concept, as 

The STABL battery system for the two 

companies in Emsland comprises 

a total of 288 second-chance battery 

modules. Originally intended for 

installation in electric vehicles, they 

ended up on the shelf before getting 

a second chance. The usable storage 

capacity is 1,233 kWh, with an output 

of 405 kW. The purpose of the storage 

system is to smooth out peak loads 

and minimize grid charges due to 

atypical grid use. The modular design 

allows fast and versatile replacement 

of single battery modules throughout 

the service life of the system. 

Comprehensive solution with more 

than 2 MWp – and an innovative 

storage system 

Fig. 2: A stationary battery storage system from STABL Energy complements the energy 

system installed at Giga Coating and System Trailers – this allows intermediate storage 

of the self-generated solar power, controlled distribution of peak loads, and substantial 

reduction of electricity costs. 




Storage capability overcomes 

disadvantages 

The commercial storage unit is very 

important in that it offers independence 

from the daily changing dynamics 

of the electricity market. This 

eliminates the necessity of immediately 

feeding unneeded electricity 

into the grid – with the aforementioned 

costly consequence of a negative 

electricity rate due to the surplus. 

Conversely, a company can purchase 

electricity at favorable times and 

keep it in the storage system until it 

is needed. Project manager Lennart 

Oklitz: “A comprehensive system like 

the one we have implemented here 

at Giga Coating and System Trailers 

offers companies so many more 

possibilities to reduce their energy 

costs than would be possible with a 

simple PV system on the roof.” 

But the storage system is not 

the final development in the energy 

system at the affiliated companies 

in Twist: Giga Coating and System 

Trailers are meanwhile partners for 

a pilot project at Greenflash that 

demonstrates the capabilities of the 

AI-based energy management system 

– Greencore AI – in practice. “Simply 

put, Greencore AI controls an energy 

system in such a way that the customer 

always gets the best electricity 

rate in the end,” says Lennart Oklitz. 

“As soon as it becomes apparent that 

the electricity rate will be negative, 

our AI-based software intervenes to 

prevent electricity from flowing into 

the grid, thus eliminating the associated 

costs. We already have examples 

from the field that have enabled 

savings in the five figure range thanks 

to Greencore AI. 

Greencore AI unlocks 

the full potential 

But the system is capable of much 

more, and Greenflash provides its 

customers with software tools that 

allow them to see in detail how the 

intelligently controlled energy system 

works. For example, how it responds 

to peak loads, how it accesses the 

storage, and what happens in the 

case of atypical grid use. “One recent 

example: Giga Coating wanted to find 

out from the power utility whether 

better rates would be possible if 

they unloaded their stored energy 

from afternoon to evening in order 

to lower their consumption,” says 

Oklitz. “Our task was to implement 

this request in the system control. 

In cooperation with the power utility, 

which had to implement several 

Driving the world 

conversions, we quickly achieved that 

goal with Greencore AI.” 

The handling of atypical grid use 

is already fully integrated in Greencore 

AI, including the visualization 

of mixed operation with the storage 

system. Numerous additional functions 

of the new software are still 

under development, some of which 

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SEW_MOVI-C_148x210_EN.indd 1 02.10.2025 09:24:37 

31


have already proven their potential 

in the field with pilot customers like 

Giga Coating and System Trailers. For 

example, the learning system reliably 

predicts consumption, and also displays 

all relevant data such as production, 

consumption, delivery, and 

procurement. “The forecast data for 

production and consumption allows 

us to control all processes so that the 

energy costs for our customers are 

always within the optimum range,” 

sums up Lennart Oklitz. 

Further expansion planned 

Fig. 3: : Inside the 20-foot container, in which the modular energy storage system from 

STABL is installed; one can clearly see the individual battery modules, which in this solution 

consist of electric car batteries that were never used in vehicles. Image: Greenflash GmbH 

The two companies in the Emsland 

region are already well on their way 

to a greener power supply. Giga Coating 

and System Trailers are planning 

to install further energy storage systems, 

to become even more self-sufficient, 

and to increase electrification, 

for example by using high-temperature 

heat pumps. Lennart Oklitz is 

convinced that companies with energy-intensive 

production processes 

can benefit tremendously from the 

transformation to renewable energies 

by using an intelligent, comprehensive 

energy system: “That it works 

and provides tangible benefits is 

apparent in the case of our pilot customers 

for Greencore AI in a way that 

sometimes even surprises us. The 

potential is enormous.” 

The Autor: 

Fig. 4: The graphic shows how the AI-based software Greencore AI from Greenflash is 

integrated in the intelligent energy system. 


Hendrik Knese 

Technical Sales Representative 

Greenflash GmbH 

Limbecker Platz 1 

45127 Essen, Germany 

E-Mail: info@greenflash.de 

www.greenflash.de 


Companies - Innovations - Products 

Bosch commissions its first in-house 

electrolyzer with Hybrion electrolysis 

stacks 

Inauguration of the hydrogen landscape at Bosch’s Bamberg plant 

– Bosch Hybrion PEM electrolysis stacks produce hydrogen 

in real operation 

– 2.5-megawatt electrolyzer produces up to 1 metric ton of 

hydrogen daily 

– Hydrogen landscape in Bamberg showcases Bosch systems and 

solutions along the H 2 value chain 

– Markus Heyn: “The official start of operations for our electrolyzer 

and the opening of the hydrogen landscape mark an important 

milestone for us.” 

Stuttgart and Bamberg, Germany – Hydrogen is on the advance 

at Bosch: after officially launching Hybrion PEM electrolysis stacks 

(PEM = proton exchange membrane) in March, Bosch has now put 

two of them into operation in an electrolyzer at its Bamberg site. With 

a total output of 2.5 megawatts, it converts water into hydrogen and 

oxygen using renewable electricity – and meets the EU’s requirements 

for renewable hydrogen. At the same time, the commissioning of the 

electro lyzer in Bamberg marks the start of a new chapter: it is part 

of an entire hydrogen landscape built to demonstrate various ways 

of producing, storing, and using hydrogen. “Hydrogen plays a central 

role in a climate-neutral world, which is something we’re committed to 

achieving as a society in Germany and Europe, and it’s an ideal energy 

source. It can be produced, stored, and transported almost anywhere, 

and in a climate-neutral way. For Bosch, hydrogen continues to be a 

strategically important business,” says Dr. Markus Heyn, member of 

the Bosch board of management and chairman of the Mobility business 

sector. “The official start of operations for our electrolyzer and the 

opening of the hydrogen landscape here in Bamberg mark an important 

milestone for us.” 

At the heart of the electrolyzer, which was built by FEST, a company 

based in Goslar, Germany, are two Bosch Hybrion electrolysis stacks 

manufactured in Bamberg. Each of these stacks has an output of 

1.25 megawatts and produces around 23 kilograms of hydrogen per 

hour from water and electricity. At full load, the electrolyzer can produce 

more than 1 metric ton of hydrogen daily. That’s enough fuel 

for an electric 40-ton truck fitted with a Bosch fuel-cell power module 

(FCPM) to travel up to 14,000 kilometers. 

The Bamberg hydrogen landscape features just such an FCPM, 

equipped with a Bosch fuel-cell stack, in continuous operation inside a 

“lifetime container” with a view to testing the module’s durability. The 

hydrogen to power the FCPM flows into the container from the electrolyzer 

via a pipeline network. Here, the hydrogen-producing process that 

previously ran in the PEM electrolysis stacks is now reversed: hydrogen 

and oxygen are fed into the FCPM’s fuel-cell stacks, where they react to 

produce water and electrical energy. The electricity generated by the 

FCPM flows back into the electrolyzer, where it is used both to test the 

electrolyzer and to produce hydrogen locally. These around-the-clock 

tests inside the lifetime container simulate a wide range of usage scenarios 

to ensure the durability and reliability of the FCPMs. Large-scale 

production of the FCPM started in Bosch’s Stuttgart-Feuerbach plant 

in mid-2023. It was recently nominated for the prestigious German 

President’s Future Prize. “Bosch can do hydrogen, and at scale,” says 

Thomas Pauer, the president of the Power Solutions division. “We got 

involved in the area at an early stage, made upfront investments, and 

are now offering market-ready technical solutions. That includes our 

fuel-cell power module. The fact that it was nominated for the German 

Future Prize proves that this Bosch technology is at the cutting edge. 

And that applies both to the fuel cells and to the electrolysis.” 

Bamberg also has a second test station for the Hybrion PEM electrolysis 

stacks manufactured at the plant there. Before delivering stacks 

to customers, this is where Bosch ensures that they reliably achieve 

their performance and efficiency under real operating conditions. For 

example, various load profiles are simulated to test the reaction of 

each stack to electrical fluctuations. In addition, every Hybrion stack is 

activated before delivery so that it is immediately ready for use at the 

customer’s premises. Another feature of the hydrogen landscape is the 

21-meter-high hydrogen tank, in which hydrogen from electrolysis can 

be stored at up to 50 bar. 

Bosch has already reached its first milestones in electrolysis technology 

in 2025. Following the market launch in the spring, deliveries have 

begun to various customers and partners, including companies such 

as IMI, Kyros Hydrogen Solutions, Neumann & Esser, Pietro Fiorentini, 

and the latter’s subsidiary Hyter. 

Robert Bosch GmbH 

Robert-Bosch-Platz 1 

70839 Gerlingen-Schillerhöhe, Germany 

kontakt@bosch.de 

www.bosch.de 

Retrofitting earthing systems: 

a breeze with the DEHN earth rod set 

Performance and efficiency tests ensure that every Hybrion stack manufactured in 

Bamberg complies with Bosch’s high quality standards. 

Image: Bosch 

Retrofitting earthing systems in existing buildings poses challenges 

for owners and specialised companies. A functioning earthing system 

is essential, especially when it comes to renovations, energy 

modernisations or the installation of photovoltaic systems, wall 

boxes and heat pumps. However, many existing buildings lack proof 

of standard-compliant earthing or use outdated systems such as 

water pipe networks. In addition, limited space, sealed surfaces and 

33


difficulty accessing the soil often make conventional retrofitting a 

complex and costly undertaking. With the new D18014 earth rod 

set, DEHN provides a practical solution specially developed for the 

requirements of renovating existing buildings. 

To comply with standards, the electrical installation must be equipped 

with a functional earthing system that safely conducts fault currents 

to earth, thereby ensuring its safety and functionality. It protects 

people from hazards, such as lightning exposure, and prevents fires. 

In Germany, an earthing system is a standard requirement for electrical 

installations, especially in new buildings. But owners of existing 

buildings often deliberate on whether retro-fitting is mandatory when 

they embark on a renovation or modernisation project. Although there 

is no general obligation to renew the entire electrical installation in 

older buildings, newly installed or modified system components, such 

as technical extensions relating to renewable energies, must comply 

with the applicable safety and technical standards. The relevant standards 

for the installation of an earthing system are DIN VDE AR-N 4100 

and DIN 18014. 

The D18014 earth rod set from DEHN contains all the necessary components 

for the professional installation of earth rods and is particularly 

suitable for new buildings and existing buildings with limited soil 

Standardised, efficient and easy to 

install: The D18014 earth rod set from 

DEHN for retrofitting earthing systems 

 

Image: DEHN SE 

or minimal excavation possibilities. 

Whatever the season, 

the earth rod solution 

ensures and maintains stable 

earth resistance regardless of 

weather conditions or soil moisture. 

The set meets all relevant 

standards by complying with 

the requirements of DIN 18014 

and the applicable VDE specifications. 

Its versatility makes it 

suitable for a variety of applications, 

including partial renovations, 

selective upgrades, 

installation inside the building 

or a complete renewal of the 

earthing system. 

The set consists of five earth 

rods, each 1 metre long, to 

be inserted into the ground. 

A driving spike makes it easier to drive in the rods. The earth rods 

are connected to the connecting cable (round wire 8–10 mm or 

cable 16–50 mm 2 ) without a cable lug using a connection clamp. This 

establishes a secure connection between the earthing system and the 

main earthing busbar (MEB) of the electrical installation. For buildings 

with a foundation area of up to 200 m², two sets are required to meet 

the normative requirements. Installation involves minimal disruption 

of existing outdoor facilities. Only two small excavation sites and wall 

bushings are necessary. 

Prevalon Energy and Emerson 

announce global strategic collaboration 

to deliver integrated power and 

energy storage solutions for data 

centers 

Strategic alliance combines advanced battery energy storage, 

automation, and control technologies to drive next-generation 

data center resilience and efficiency 

HPrevalon Energy LLC, a leader in integrated battery energy storage 

systems and Emerson, an industrial technology leader delivering 

advanced automation solutions, announced a strategic collaboration to 

deliver advanced, integrated energy solutions for the global data 

center industry. 

The collaboration brings together Prevalon’s HD5 Energy Storage 

Platform and insightOS Energy Management System with 

Emerson’s Ovation Automation Platform, creating a unified approach 

to energy resilience, grid reliability, and system intelligence. Together, 

the companies will support hyperscale, colocation, and enterprise data 

centers in achieving the highest levels of performance, uptime, and 

sustainability. 

“Our alliance with Emerson marks an important milestone in the evolution 

of data center energy systems,” said Tom Cornell, President and 

Chief Executive Officer of Prevalon Energy. “By integrating our storage 

and energy management platforms with Emerson’s proven power 

plant control technologies, we’re empowering data centers to achieve 

unmatched reliability and efficiency in a rapidly electrifying digital 

economy.” 

“This collaboration unites two complementary technologies to transform 

how power is produced, stored, and delivered to mission-critical 

data center operations,” said Michael McManus, Chief Strategy Officer 

at Prevalon Energy. “Together, we’re building the resilient, intelligent 

infrastructure that the global data center community depends on.” 

“We are excited to join forces with Prevalon Energy to redefine how 

data centers manage and optimize their energy. By combining 

Emerson’s deep industry expertise and innovative automation technologies 

with Prevalon’s advanced energy storage solutions, we are 

enabling data centers worldwide to achieve unprecedented levels of 

DEHN SE 

Hans-Dehn-Str. 1 

92318 Neumarkt, Germany 

info@dehn.de 

www.dehn.de 

Prevalon’s HD5 Platform delivers 5 MWh of liquid-cooled, factory-tested performance 

— a fully integrated, U.S.-built energy storage system engineered for safety, 

reliability, and scalability 

34


efficiency, resilience, and sustainability,” said Bob Yeager, president 

of Emerson’s power and water solutions business. “This collaboration 

reflects our commitment to delivering integrated technologies 

that meet the demands of a rapidly evolving digital economy. We are 

turning the vision of fully integrated, next-generation energy systems 

into reality for the global data center industry.” 

Through this teaming agreement, Prevalon and Emerson will jointly 

pursue opportunities to integrate advanced control, automation, and 

energy storage systems for data center clients worldwide. The companies 

will coordinate marketing, development, and customer engagement 

initiatives to accelerate the adoption of next-generation energy 

technologies into data center applications. 

For more information, visit 

PrevalonEnergy.com and Emerson.com 

HOERBIGER supplies three 

HCP 500 Hydrogen Compressor Packages 

for Hamburg Green Hydrogen 

Hub in Germany 

The Hamburg Green Hydrogen Hub (HGHH) plans to build a new 

105-megawatt hydrogen plant on the site of the former Moorburg 

coal-fired power plant by 2027. The aim is to produce green hydrogen 

for a wide range of applications in mobility and industry. 

The German company Kraftanlagen Energies & Services has been commissioned 

to build the infrastructure around the electrolyzer. Kraftanlagen, 

in turn, has entrusted HOERBIGER with the delivery of three HCP 

500 Hydrogen Compressor Packages. 

Kraftanlagen has decades of experience in energy technology and 

plant engineering and has successfully implemented numerous hydrogen 

projects in recent years. 

At the heart of the HGHH is the HCP 500 Hydrogen Compressor Package 

from HOERBIGER, which ensures safe, reliable and cost-effective hydrogen 

compression for large scaled hydrogen applications such as trailer 

filling. Users benefit from an innovative and compact design as a turn key 

solution with fast filling capacities. With a high degree of standardization, 

the HCP 500 is optimized for the lowest total cost of ownership (TCO). 

As the technology leader for the next generation of efficient hydrogen 

compressor packages with more than 130 years of experience in 

compression, HOERBIGER is driving the industrialization of hydrogen 

industry and mobility applications. 

HCP 500 – flexible solution for high mass flow hydrogen compression 

Utilizing Ariel Corporation’s KBH compressor, the high mass flow of 

the HCP 500 of over 250 kg/h makes the compressor package from 

HOERBIGER the ideal solution for trailer filling facilities and heavy-duty 

refueling stations, ensuring unmatched operational experiences for 

both stationary and intermittent operating conditions. 

The compressor package HCP 500 is featured by HOERBIGER’s leading 

components such as CP valves and sealing elements that guarantee 

high durability and availability as well as the Electric Stepless Capacity 

Control System – eHydroCOM, which offers unique controllability of 

the compressor flow rates in terms of efficiency and precision. The 

eHydroCOM allows a large operating window of the compressor which 

ensures perfect alignment with the requirements of the electrolysers 

and the attached trailer filling application. 

HOERBIGER Wien GmbH 

Seestadtstr. 25 

1220 Wien, Austria 

info@hoerbiger.com 

www.hoerbiger.com 

HORIBA introduces CCM/MEA 

Catalyst Coating Monitor XV-100 

Helping streamline the production of PEM 1 fuel cells and water 

electro lyzers, and reducing the cost of noble metal catalysts. 

HORIBA Jobin Yvon GmbH (hereinafter “HORIBA”), a leading provider 

of measuring and testing solutions for a wide range of applications, 

proudly announces the launch of the CCM/MEA 2 

catalyst coating 

monitor XV-100. This groundbreaking solution is designed to streamline 

the roll-to-roll coating 3 process of catalyst layers in PEM fuel cells 

and electrolyzers, which are key technologies in the transition to a 

hydrogen-powered, carbon-neutral society. 

In recent years, hydrogen has been attracting attention as an important 

energy source, and demand for fuel cells and water electro lyzers is 

growing rapidly. However, towards realizing a carbon-neutral society, 

many challenges have been emerging in the hydrogen market, which is 

experiencing accelerated technical development worldwide. One such 

challenge is improving the performance of PEM fuel cells and water 

electrolyzers, which rely heavily on noble metal catalysts, such as platinum 

and iridium. This has a high-cost burden and leads to problems in 

controlling the amount of coating applied or the thickness of the metal. 

The XV-100 provides optimization of the coating process and minimize 

material waste through non-destructive, non-contact, inline measurement 

during roll-to-roll processes. Leveraging HORIBA’s advanced 

35


Optimise biogas production with the 

innovative BIO-ROXX mixing module 

from Wangen Pumps 

Unique mixer design delivers homogenous inoculum and efficiently 

removes solid bodies 

Optimising biogas production in an Anaerobic Digestion plant 

requires a perfect mix of liquid and dry feedstocks, the elimination of 

contaminants and solid bodies. The BIO-ROXX module from Wangen 

Pumps accelerates the fermentation process and increases the biogas 

yield by mixing solid and liquid phases to prepare the ideal inoculum, 

limiting air introduction to a minimum and removing solid bodies such 

as stones. 

CCM/MEA Catalyst Coating Monitor XV-100 

Image: HORIBA 

X-ray fluorescence (XRF) technology, the XV-100 delivers continuous, 

real-time monitoring of catalyst coating with an industry-leading 

response time as low as 0.01 seconds 4 . This enables precise control 

overcoating quantity and uniformity, directly contributing to higher 

production yields, improved quality control, and significant cost reductions. 

Even when multiple units are used in each process, centralized 

data measurement enables improvement of work efficiency and saves 

manpower. Furthermore, customizable engineering services are available, 

including the construction of a traverse mechanism 5 and the provision 

of data management solutions, allowing us to tailor our support 

to meet each customer's needs. 

Dr. Ingo Reese, Head of Sales at HORIBA Jobin Yvon GmbH, “to support 

pathing the way to a carbon neutral society we provide highly innovative 

measurement driven technology that supports our customers 

for all kinds of processes in order to intelligently generate, store, 

and use new energy sources such as hydrogen. With the new XV-100 

we extended our portfolio with a state-of-the-art solution for various 

kinds of coating process improving not only the efficiency of those processes 

itself but also the economic efficiency in terms of cost and time 

savings.” 

1 

Polymer Electrolyte Membrane. 

This electrolyzes water to produce hydrogen. 

2 

CCM: Catalyst Coated Membrane, MEA: Membrane Electrode 

Assembly. Both are critical components of PEM fuel cells and 

water electrolyzers. 

3 

A processing method in which a rolled base material is subjected to 

processing such as printing or coating, and then rolled up again. 

4 

As of February 2025. In an X-ray fluorescence analyzer (analysis by 

HORIBA, Ltd.). Results may vary depending on use and conditions. 

5 

A system of devices for moving an object to any position. 

HORIBA Jobin Yvon GmbH 

Hans-Mess-Str.6 

61440 Oberursel, Germany 

www.horiba.com 

Installed downstream of the dry substrate hopper and the liquid feeder 

and before the fermenter, the Wangen Pumps BIO-ROXX module 

delivers a homogeneous substrate that increases the decomposition 

rate in the Anaerobic Digestion plant and speeds up gas production. 

Ideal for plant sizes of 1-10 MW, the BIO-ROXX module is a real asset 

in bio methane production, where high gas purity must be attained to 

meet the grid’s standards. 

Improving biogas production 

The BIO-ROXX features a sealed mixing chamber combined with a discharge 

pump below the fill line, so no air can enter and compromise 

the Anaerobic Digestion process. The unique configuration of the mixing 

rods and blades inside the chamber ensures that organic solids 

are evenly suspended and diluted, enabling the anaerobic bacteria to 

thrive and convert the organic materials to biogas. The mixing process 

enhances the efficiency of the fermenter by reducing viscosity and 

preventing the formation of a 'float' layer, which occurs when larger, 

fibrous solids accumulate as a crust on top. By preventing floats and 

The new BIO-ROXX module from 

Wangen Pumps supports efficient biogas 

and biomethane generation by 

preparing the substrate, mixing solids 

and liquid together, and removing 

contaminants like stones and metal. 

assuring low viscosity levels, the 

BIO-ROXX maintains optimal gas 

production, reduces the energy 

consumption of mixers, and 

prevents damage to the paddles 

used for stirring the fermenter 

contents. 

Reliable contaminant removal 

Contaminants such as air can 

inhibit efficient biogas production. 

Stones, glass, wood, and 

bits of metal can settle at the 

base of a fermenter, reducing 

tank capacity over time. They 

can also cause damage, blockages, 

or breakages to pipelines, 

pumps, and other equipment. 

Organic substrates with a dry 

content of up to 18 % pass 

through the BIO-ROXX at a 

rate of more than 85 m 3 /h 

(22,484 gal/h). The dwell time in 

the unit enables solid contami 

36


nants to gravitate to the bottom of the mixing chamber, where they are 

caught in a trap and can be safely expelled. This prevents solid bodies 

from entering the fermenter and avoids the need to empty the digestion 

tanks to remove them or repair damage. 

Highly adaptable technology 

The Wangen Pumps BIO-ROXX can process organic materials from 

a wide variety of sources, including straw, maize stalks, whole-crop 

silage, manure, and food waste. Where fibrous materials of more than 

30 cm in length are common in the substrate, the BIO-ROXX is often 

used in conjunction with a hammer mill, an extruder or a macerator 

for improved operational productivity. 

The BIO-ROXX, with its robust yet streamlined steel construction, is 

engineered to operate seamlessly in both mesophilic and thermophilic 

Anaerobic Digestion processes. It can deal with an inoculum of up to 

18 % dry matter content and is designed to perform reliably in harsh 

conditions, including high temperatures. Combined with its ability to 

handle a diverse and expanding range of substrates, these features 

make the BIO-ROXX an ideal choice for Anaerobic Digestion plants 

worldwide, offering a cutting-edge response to the evolving needs of 

the biogas industry. 

store liquid substrates. “Despite its size, the plant, with an annual processing 

capacity of 165,000 tonnes, will be built in just six months of 

pure construction time. Construction is proceeding according to plan 

and mechanical completion is scheduled for the end of this year,” says 

Tobias Gerweler, Managing Director of WELTEC BIOPOWER. “The decision 

not to use grass silage was a conscious one, so that we would not 

be competing with the livestock industry,” Patrick Meade continues. 

A combined heat and power plant (CHP) installed on site generates 

around 1 megawatt of power for the operation of the plant and supplies 

heat for the digesters. 

Hourly production of 1,300 cubic metres of biomethane 

Three rotating long-axis agitators and three submersible motor agitators 

in the tanks support the effective digestion of the substrate mix. 

The biogas is collected in the digesters with double-membrane roofs 

and processed into biomethane using membrane technology. It then 

enters the public gas grid 20 metres away via the feed-in point. Once 

commissioned, the plant will produce around 1,300 standard cubic 

metres of biomethane per hour – equivalent to around 110 GWh of 

energy per year. The annual output of 65,000 tonnes of digestate is 

stored in a covered concrete lagoon and delivered to farmers separately 

as liquid and solid fractions. 

Find more information about Wangen Pumps BIO-ROXX module here: 

www.wangen.com/de/produkte/bio-roxx-1148 

Pumpenfabrik Wangen GmbH 

Simoniusstr. 17 

88239 Wangen, Germany 

mail@wangen.com 

www.wangen.com 

Ireland: WELTEC BIOPOWER 

bio methane plant to go into operation 

in mid-2026 

Biomethane from beer and whiskey industry residues 

German manufacturer WELTEC BIOPOWER is currently building 

a biomethane plant for the Irish company Evergreen Agricultural 

Enterprises Limited. The plant at the company’s headquarters in 

Monasterevin, County Kildare, will go into operation in mid-2026 

after a total construction period of 11 months. The location offers 

the operator logistical advantages, among other things: “On the 

one hand, it is well connected to the M7 motorway. In addition, 

the national gas network for direct biomethane feed-in is in the 

immediate vicinity,” emphasises Patrick Meade, Managing Director 

of Evergreen. 

By 2030: 5.7 terawatt-hours of biomethane per year 

“The fact that German manufacturer WELTEC BIOPOWER was awarded 

the contract to build the largest plant in Ireland to date was due not 

only to the technical advantages mentioned above, but also to the 

short delivery times,” emphasises Managing Director Patrick Meade. 

This will also enable Ireland to achieve its ambitious expansion 

targets for biomethane production: the government aims to produce 

5.7 terawatt-hours (TWh) of biomethane annually by 2030. To achieve 

this, existing biogas plants for biomethane processing would have to 

be expanded, and technically mature plants such as the one built by 

Evergreen in Kildare would have to be planned and constructed. 

WELTEC BIOPOWER GmbH 

Zum Langenberg 2 

49377 Vechta, Germany 

info@weltec-biopower.de 

www.weltec-biopower.com 

No competition with feed production for use of input materials 

The € 50 million project comprises four digesters and one stainless-steel 

secondary digester, each with a volume of 4,900 cubic 

metres. These are mainly used to ferment production residues and 

by-products from the Irish beer and whiskey industry. The materials 

are readily available and do not compete with feed production, as 

they are unsuitable for animal feed. Three additional tanks are used to 

German manufacturer WELTEC BIOPOWER is currently building a biomethane 

plant for the Irish company Evergreen Agricultural Enterprises Limited. 

37

Brand name register 

BAUER KOMPRESSOREN GmbH 

Stäblistr. 8 

81477 München/Germany 

Phone: +49 (0)89 78049-0 

Fax: +49 (0)89 78049-167 

E-mail: industrie@bauer-kompressoren.de 

Website: www.bauer-kompressoren.de 

BAUER KOMPRESSOREN is one of the leading 

manufacturers of medium and high-pressure system 

for the compression of air and gases worldwide. 

- Medium and high-pressure compressors 

- 25 – 500 bar, 2.2 – 315 kW 

- Air and gas treatment 

- Storage systems 

- Air and gas distribution 

- Gas measurement systems 

- Controls 

For current trade fairs please visit: 

www.bauer-kompressoren.de/ 

news-events/trade-show-dates/ 

KAMAT GmbH & Co. KG 

Salinger Feld 10 

58454 Witten/Germany 

Phone: +49 (0)2302 8903-0 

E-mail: info@KAMAT.de 

Website: www.KAMAT.de 

High pressure plunger pumps + systems 

Mining pumps + systems 

Process pumps + Systems 

Water hydraulic pumps + Systems 

Operating pressures up to 4000 bar 

Flow rates up to 10,000 l/min 

Systems in mobile and stationary design 

KAMAT valve technology and water tools 

For KAMAT‘S current global trade fair 

partipcipations, visit 

https://www.kamat.de/en/information-centre/trade-fairs/ 

We are looking forward to your visit! 

NETZSCH Pumpen & Systeme GmbH 

Geretsrieder Str. 1 

84478 Waldkraiburg/Germany 

Phone: +49 (0)8638 63-0 

E-mail: info.nps@netzsch.com 

Website: 

www.pumps-systems.netzsch.com 

As a specialist for complex fluid handling, 

NETZSCH develops customised and sophisticated 

pump solutions on a global level. The product 

spectrum ranges from the industry’s smallest 

metering pumps to high-volume pumps for 

applications in the oil & gas or mining industries. 

NETZSCH offers NEMO ® progressing cavity pumps, 

TORNADO ® rotary lobe pumps, NOTOS ® multi screw 

pumps, PERIPRO ® peristaltic pumps, grinders, dosing 

technology and barrel emptying units, accessories 

and service. 

For current trade fairs, please visit: 

www.pumps-systems.netzsch.com/ 

en/events 

SEEPEX GmbH 

Scharnhölzstr. 344 

46240 Bottrop/Germany 

Phone: +49 (0)2041 996-0 

E-mail: info@seepex.com 

Website: www.seepex.com 

SEEPEX is one of the leading worldwide specialists in 

the field of pump technology. 

Our portfolio comprises progressive cavity pumps, 

pump systems, and digital solutions. 

Our pumps are used wherever low to highly viscous, 

aggresive or abrasive media must be conveyed at 

low pulsation rates. 

Please visit our website for 

upcoming exhibitions 

www.seepex.com 

SEW-EURODRIVE GmbH & Co KG 

Ernst-Blickle-Str. 42 

76646 Bruchsal/Germany 

Phone: +49 (0)7251 75-0 

Fax: +49 (0)7251 75-1970 

E-mail: sew@sew-eurodrive.de 

Website: www.sew-eurodrive.com 

SEW-EURODRIVE is one of the global market leaders 

in drive technology and automation. 

The company has 17 production plants and 92 Drive 

Technology Centres in 56 countries. 

The company was founded in 1931. 

The headquarters are located in Bruchsal, Germany. 

Turnover in the 2023 financial year totalled over 

4.5 billion euros. 

Around 22,000 employees work for 

SEW-EURODRIVE. 

Current trade fair dates can be found 

on the website 

www.sew-eurodrive.de/trade-shows 

We are looking forward to your visit! 

VEGA Grieshaber KG 

Am Hohenstein 113 

77761 Schiltach/Germany 

Phone: +49 (0) 7836 50-0 

E-mail: info.de@vega.com 

Website: www.vega.com 

Product portfolio: 

As one of the world’s leading suppliers of level and 

pressure sensors, VEGA offers precise measurement 

technology that meets the stiff requirements of the 

hydrogen industry. Our 2,600 employees in more 

than 85 countries are at your side to find the right 

solution for your application. 

Reference Exhibitions: 

www.vega.com/en-de/company/ 

news-and-events/exhibitions 

Index of Advertisers 

BAUER KOMPRESSOREN GmbH page 27 

Filtech Exhibitions Germany GmbH & Co. KG page 19 

GEA Group Aktiengesellschaft 

4. Cover page 

IVS – Industrial Valve Summit 

3. Cover page 

KAMAT GmbH & Co. KG page 21 

NETZSCH Pumpen & Systeme GmbH page 13 

SEEPEX GmbH 

Cover page 

SEW-EURODRIVE GmbH & Co. KG page 31 

VEGA GmbH 

2. Cover page 

38

EnErgy-EfficiEnt 

and SuStainablE 

SolutionS 

GEA provides turnkey refrigeration and heating systems, customized 

solutions, compressors and compressor packages, chillers, controls, and 

heat pumps that meet precise temperature requirements. Comprehensive 

service programs and digital products support our customers throughout 

the entire lifecycle of their systems and equipment to ensure peak 

performance. 

Visit us! 

HeatExpo 

November 25–27, 2025, Dortmund

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