Fackelmann is a household name in the truest sense of the word. From toothpicks to baking tins, knives and pots to bathroom furniture, the range of products of the specialist for kitchen helpers and household articles, founded in 1919, is extensive. Furniture production began at the company's headquarters in Hersbruck, Franconia, as early as 1963. Since its beginnings, the company has grown enormously in terms of its turnover and its workforce as well as in terms of its floorspace. Administration buildings, production halls and logistics areas are lined up close together in Hersbruck on around 50,000m2. The heating system with several heaters working in parallel grew rather unplanned during all that time. In 1978, Fackelmann had already invested in the first biomass heating system, in which the residual wood from furniture production was used to generate energy. The follow-up system installed around the turn of the millennium was replaced in 2019 by an underfeed combustion system from ENDRESS. By virtue of intelligent, modern technology and excellent planning in cooperation with the Hersbruck-based plant engineering company Grötsch Energietechnik, it now supplies production, warehouses and administration with energy via a local heating network. Buying oil or natural gas is a thing of the past for the Fackelmann Group, which operates sustainably in all respects.
Underfeed combustion USF-W 1000 | 900-1100 kW
Tubular fabric filter RGF
The challenge:compact wood combustion system for confined spaces
An actual-state analysis of the existing heating system revealed something astonishing as part of a bachelor's thesis commissioned by Fackelmann: the boiler of the old wood combustion system was completely oversized with a rated output of 2.5 MW. They also wanted to change the fact that the two floors in the boiler house were occupied by a more compact heating system. The desire was to house them on one level to shorten the distances for maintenance staff. Last but not least, a wood combustion system of this size falls under the scope of the Fourth Ordinance on the Implementation of the Federal Immission Control Act (Ordinance on Installations Requiring a Permit – 4th BImSchV) and must go through an elaborate immission control approval process by the authorities.
A final, decisive criterion in the selection of the appropriate combustion technology was the fuel. Furniture production normally produces a high proportion of dust and chips. Lump wood and sorted solid wood pallets only form a small part of the fuel. This is where ENDRESS came in with many good arguments against grate firing and in favour of modern underfeed combustion, in which the fuel is fed into the combustion chamber from below. "With underfeed combustion, the fuel burns from above and there is hardly any turbulence, which increases the amount of dust in the flue gas". explains Managing Director Klaus Endress and continues: "By virtue of the advanced control of the combustion process, slag cannot be deposited in excess on the inner wall of the boiler either."
"Within a very short construction period, we were able to carry out the installation together with our partners and thus take another step towards environmentally friendly operation."
Horst Bär, Managing Director Production at Fackelmann
The solution:Underfeed combustion plus buffer tank
Despite a nominal output of "only" 990 kW compared to the old system, the new USF-W 1000 Underfeed combustion system from ENDRESS has excellent efficiency, is more compact and also has significantly reduced exhaust gas emissions of dust, CO and NOx. The plant therefore no longer falls within the scope of the 4th BImSchV. The buffer storage tank was dimensioned to the maximum in order to balance the load peaks during increased heat demand.
In order to be able to install the system at ground level in the boiler house, the boiler was designed with a lower height than usual. Immediately next to it, the 23.5m3 buffer storage tank was accommodated over two floors. By virtue of the ENDRESS RGF 1000 particulate matter filter developed in-house, emissions remain below the limit value of 0.02 g/m³ (according to the 1st BImschV).
ENDRESS systems are extremely low-maintenance, robust and wear-resistant. It is no coincidence that we provide a 10-year guarantee on our boilers. A maintenance contract was concluded with Fackelmann to ensure operational safety in all cases. The online service I-SPY enables the employees to access the system control and they can react immediately in case of malfunctions.
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ENDRESS adapts your new combustion plant individually to your annual heat requirements, the type and quantity of waste wood produced and the space available on your site. Each offer is combined with a specific installation proposal.