By investing in Danfoss VLT® drives, the Roca Group factory in Gliwice now consumes about 30% less energy, annually.
POLAND: The Gliwice ceramic sanitary ware factory – a member of leading bathroom industry manufacturer Roca Group - was facing high energy costs, which in the ceramics sector can constitute as much as 30% of total production costs. Manufacturing processes such as mixing ceramic clay, glazing, and firing not only generate significant operating costs, but also have significant environmental impact.
In the face of these challenges, the Roca Group has been focusing for years on achieving sustainable development goals, including decarbonization, circular economy, and optimization of resource use in production. The company sought solutions that would reduce energy consumption and operating costs, while supporting long-term ESG initiatives.
Sustainability is at the heart of everything we do - from product development, material sourcing, production, logistics, packaging and transport to promoting responsible product use practices. Roca is a member of the UN Global Compact Initiative, pursuing the Sustainable Development Goals. The most important one is to achieve climate neutrality in 2045. So far, counting from 2018, Roca Group has reduced water consumption by 53% and energy consumption by 50% globally
The challenge: Investment in energy efficiency
During a site visit, experts from Danfoss partner Control-Service identified that the factory's ventilation, conveyor, and mixer systems could benefit from energy optimization. The equipment ran at constant speed, irrespective of real-time demand, leading to inefficiency and wasted energy. A modernization of the drive systems was necessary, including the implementation of variable frequency drives (VFDs) to modulate machine operation based on actual process needs.
The challenge lay in persuading the factory to invest in these modern technologies. Although requiring upfront capital expenditure, the investment promised substantial long-term cost savings.
The solution: Test and validation with Danfoss drives
Control-Service proposed a test installation of variable frequency drives (VFDs) on the ventilation system, adding flow and temperature sensors to regulate fan speed and the number of active devices.
The tests demonstrated that, frequently, a single fan could adequately handle the load, replacing the need for multiple fans. Following successful validation, Roca opted for a comprehensive rollout of VFDs across the factory, encompassing fans, mixers, pumps, and conveyor belts.
A total of 45 drives (VFDs) were installed over three years. In addition, operational risk audits have helped to ensure uninterrupted operation since 2007. Regular servicing and repairs carried out by Danfoss partner Control-Service guarantee that equipment remains in perfect working order, eliminating the need for frequent device replacement.
The operating risks of the VFDs are periodically reviewed by Control-Service specialists. Such a system brings significant environmental benefits, minimizing an energy-intensive recycling process but also - above all – avoids the purchase of new equipment and unnecessary waste management
During each on-site audit, specialists assess operational risk by verifying the equipment for efficiency and the ability to continue uninterrupted operation. They also assess the operating environment. For example, above-average temperatures in the hall make it particularly relevant to check fan operation, heat-sink temperature, and contact pressure in the drives. Dust can settle on electronics, so components should also be cleaned regularly.
The outcome: 30% less energy consumption
The implementation of variable speed control using drives enabled the Roca Group to achieve an approximate 30% reduction in energy consumption at its Gliwice factory, resulting in substantial financial savings and a decrease in CO₂ emissions.
The initial investment paid for itself in just 7 months, freeing up resources for process improvements. Regular audits and servicing ensure long-term equipment performance and prevent costly replacements.
In short, the Gliwice factory demonstrates how drive technology investments can simultaneously boost business and sustainability goals.
Our investment in Danfoss drives, which lowered the average motor speed in our HVAC systems, had a payback period of only 7 months. As a result, we expanded our partnership, and Control-Service has now installed a total of 45 units at our site over the past three years. These drives enable us to save approximately 30% on our annual energy consumption, opening up new avenues for process optimization.
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