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Heidelberg: CombiStar Upgrade boosts energy efficiency

Heidelberg is systematically improving on sustainable print production. The new-generation Combistar is meant to reduce waste – the primary factor in improving sustainability – and boost energy efficiency.

The CombiStar Pro combines dampening solution conditioning with inking unit temperature control. It also incorporates free-cooling technology for further energy savings. Image: Heidelberger Druckmaschinen AG

In the new CombiStar, the inking unit pump for temperature control circulation is fitted with an electronically controlled drive and the refrigerating units now have an energy-efficient digital scroll compressor. Stepless adjustment of the refrigerating units to the cooling capacity required by the machine significantly boosts the system's efficiency.

During a field test at printing company Häuser KG in Cologne, a CombiStar cabinet from the previous generation and a cabinet with the energy-efficient design of the new generation were fitted with electricity meters and the electricity consumption was recorded over a period of ten months. "The energy-efficient CombiStar used 34 percent less power than the older CombiStar unit," says a delighted Heiko Mazur, owner and managing director of Häuser KG. "Calculated over an entire year, this adds up to energy savings of 15,000 kWh. Based on the total electricity consumption of all the presses, which amounted to 250,000 kWh, this represents a saving of no less than six percent,"

The free-cooling function can optionally be integrated directly into the equipment cabinet of the CombiStar Pro from Heidelberg. If outdoor temperatures rise above 15°C, the active refrigerating unit is switched on in stages to assist cooling. From approximately 20°C, it provides 100 percent of the cooling capacity required. If the outdoor temperature drops, the active refrigerating unit is deactivated in stages. The efficiency of this system thus depends on the outdoor temperature, the design of the recooler - the bigger the better - and the temperature specified in the inking unit.
Saving energy is one of the most important challenges for the future print industry. Targeting the third most energy intensive part in a printing press (fourth in presses with dryers), Heidelberg demonstrates their systematic solution to the problem: focus on the details and save energy with every little step.

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