USA: Across the globe, industries are facing increasing pressure to reduce their carbon footprints. Achieving ambitious emissions targets demands not just innovative solutions, but also a commitment to optimize operations at every level. For companies at the forefront of the efficiency transformation, this makes it essential to lead by example.
While known for producing some of the world’s most energy-efficient drives, the Danfoss facility in Loves Park, Illinois, US, until recently, had a ventilation system that offered an opportunity for improvement.
This is how they turned that opportunity into a high-performance ventilation system that reflects Danfoss’ commitment to energy efficiency.
The challenge: Aligning with ambitious Scope 1 & 2 targets
The original setup at the Loves Park facility relied on HVAC equipment with belt-driven centrifugal fans, running at constant speed with an average efficiency of just 50%. This setup not only consumed excessive energy, resulting in inefficient use of resources, but also conflicted with Danfoss' emissions goals.
As part of this ambitious efficiency journey, Danfoss has set reduction targets approved by the Science-Based Targets initiative. These include achieving full carbon neutrality across all facilities globally by 2030, addressing Scope 1 and 2 emissions, and reducing Scope 3 emissions by 15% within the same timeframe.
At Danfoss, we are not only helping other businesses improve their energy efficiency by providing some of the most efficient variable speed drives in the market—we have ambitious efficiency targets of our own. Our headquarters already achieved CO2 neutrality in 2022, including factory and all office buildings.
The solution: An advanced high-efficiency ventilation system
To align the Loves Park facility with the company’s Scope 1 and 2 emissions targets and reduce energy consumption, Danfoss upgraded one of the existing ventilation systems with an EC+ fan system, developed in partnership with NOVENCO, comprising the following highly efficient, best-in-class components:
- A ZerAx® axial fan for best-in-class performance
- A permanent magnet motor
- A Danfoss VLT® HVAC Drive FC 102, enabling variable speed control based on temperature needs
This streamlined system reduced the number of fans while improving overall efficiency.
The outcome: Achieving remarkable results with minimal disruption
The new ventilation solution has demonstrated impressive efficiency, reducing operational emissions and offsetting the additional emissions from the new equipment production in just 253 hours of operation.
“We determined that the EC+ fan system will help us achieve a 59.8% reduction in emissions compared to the continued use of the old system[1],” says Ryan Drabek, Product Marketing Manager at Danfoss Drives.
The impressive results stem from the unparalleled efficiency of the EC+ system. By combining the ZerAx® axial fan, permanent magnet motor, and Danfoss VLT® HVAC Drive FC 102, the solution achieves an overall system efficiency of 85%.
The upgrade process was just as remarkable as the results.
“The replacement work only took two days, which is impressive for a project of this size and was critical to our ability to commit. Like most of our customers, we consider minimizing downtime a top priority,” adds Ryan Drabek.
This successful upgrade highlights Danfoss’ commitment to driving operational efficiency while reducing emissions, to create a more energy-efficient future.
[1] Avoided GHG emissions, EC+ case, verification 2024, Charlotte B. Merlin, FORCE Technology, 19 June 2024
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Case stories from factories
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USA: The Danfoss Loves Park factory upgraded existing ventilation with the Danfoss Novenco EC+ concept, achieving a 59.8% reduction in emissions compared to the previous system.
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CHINA: Thanks to several Danfoss DrivePro® services, Dahe Paper Group, a state-owned paper mill company in China, has reduced its costs, downtime, and failure rate.
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POLAND: The new Danfoss production hall in Grodzisk Mazowiecki has reached carbon-neutrality, thanks to full electrification, energy-saving solutions such as Danfoss drives, and energy from renewable sources.
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NETHERLANDS: Discover how Huwa International Pipeline Products improved worker safety and reduced lead times on its pickling line with Danfoss VLT® AutomationDrive FC 302 and its Integrated Motion Controller (IMC).
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GERMANY: Low voltage drives enhance machine processes to improve efficiency and productivity. For manufacturing companies such as WEBER, this can lead to lower energy consumption and running costs.
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SPAIN: Highly efficient axial fans controlled by VLT® HVAC Drive FC 102 at Volkswagen Navarra, Spain, delivered 20% energy savings in AHU operation.
