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  Products & Services  Industrial Automation  References  GARDENA relies on SIMATIC Energy Management

Greater
transparency with
just one click
SIMATIC Energy Management at
GARDENA  In support of a systematic
effort to continuously improve its
products and processes, GARDENA
has implemented a comprehensive
energy management system to
provide transparency of consumption Our experts will gladly advise you.
data.
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The challenge

Greater transparency, better control

It all started with a load management system that provided GARDENA with many ideas
about what improvements could be made, and how. The company then decided to
augment the load management with a comprehensive energy management system. The
aim was not only to provide a transparent and up-to-date representation of energy
consumption in the different areas, but also to visualize it plainly in various analyses.

With an energy management system, GARDENA creates

greater transparency and better control.

GARDENA has been working for several years with a load management
system that enables the company to avoid peaks in energy consumption.
In GARDENA’s production facility in Gerstetten, Germany, numerous
injection molding machines operate in different modes. These machines
are electrically heated. In addition, there are two water-cooled systems
consisting of several interlinked cooling units. These loads are connected
to a SIMATIC powerrate system, which enables GARDENA to monitor the
situation and ensure that the power reserves are not exceeded, as
explained by Jürgen Röck, deputy head of maintenance for buildings and
systems at GARDENA in Gerstetten: “For this purpose we have developed
an activation strategy that enables us, where necessary, to recommend
In Gerstetten, the numerous machines are typically operating in
which loads can be switched off for a brief period.” This solution has different modes
proved to be very effective at GARDENA. “Over time, the company has
carried out a number of analyses with this system to identify potential
savings and to evaluate our energy consumption. The options for
analyzing and producing reports on the consumption data will now be significantly extended with a new
energy management system.”

The right data for each target group
The Gerstetten site reports energy data to Husqvarna and uses the data
for the controlling and purchasing of energy. In the future,
maintenance is also expected to be better supported by the use of
energy data. Preparing the data for the various users previously
required significant time and effort, which is why GARDENA was
looking for a system that could make the consumption data available
quickly and flexibly.
A flexible system that grows with demand
The various production machines in operation at Gerstetten is growing
and changing continuously, and this reality must also be reflected in
the energy management system. GARDENA was therefore looking for a
system that is flexible and scalable enough that the company could
subsequently extend and adapt the solution itself.
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About GARDENA

… and it just “clicked”

The “click” was surely one of the great moments in the history of GARDENA. The
GARDENA System arrived on the market in 1968: tap connector, hose connector and
watering accessory. All the components could be easily connected using one
standardized system. A success that has been the hallmark of the company to the
present day.

An innovative system achieves a breakthrough in the

market.

The company, based in Ulm, Germany, was founded in 1961 by the

businessmen Werner Kress and Eberhard Kastner. The company began
with the sale of French garden equipment before achieving a
breakthrough in the market in 1968 with the introduction of the original
GARDENA System. Today, GARDENA is the leading European brand for
high-quality garden equipment and is represented in more than 80
countries around the world. Since 2007, the company has been a member
of the Swedish Husqvarna Group, which has established a strategy called
“Sustainovate” to promote greater sustainability in all areas of business.
Not least for this reason, resource efficiency and environmental protection
are given top priority at GARDENA, according to Jürgen Röck: “A key aspect
Gardening classics: Components of the GARDENA System in their
characteristic orange here is the consumption of energy and resources. Every year we set
ourselves targets for savings that we want to achieve as part of the
Husqvarna Group – and we must also present these savings in a
transparent way. In addition, energy is an important cost factor in
production, which is why we also keep a close eye on energy consumption at the local level. For these
reasons, we recently decided to install a new system for energy management.”

The solution

One system for existing and new machines

With SIMATIC Energy Manager, SIMATIC WinCC Professional, and SIMATIC Energy Suite,
GARDENA found a solution that meets the company’s requirements for integrated
energy management and that could be easily integrated into the existing processes.

Success is the result of good teamwork.

The energy consumption figures are recorded via a total of four SIMATIC S7-1500
controllers, which act as main controllers to collect the data from the SIMATIC ET 200
Energy Meters and forward it to WinCC. Currently, about 30 injection molding
machines and 20 measuring points of the building technology are integrated in the
energy management system. During the introduction of the system, a programmer
from Siemens supported GARDENA with the configuration, but the company is also
able to manage the system itself. At the production facility, Jürgen Röck and his team
use an engineering station with SIMATIC WinCC and the Energy Suite to easily integrate
new machines or measuring points into the energy management system. “These can be
integrated into Energy Manager so that we can easily expand the system at any time,”
says Jürgen Röck. New machines are equipped with energy meters as standard, and
existing machines are being retrofitted step-by-step. In this process, GARDENA uses a
solution that does not require the machine to be completely disconnected, even if a
measuring system is immersed. This means that production is not adversely affected.
GARDENA is now further expanding its energy management system. “The aim is to The data from the SIMATIC ET 200 Energy
Search for ... Meters are 
integrate the gas consumption of our combined heat and power plant and gas heating  
recorded by SIMATIC S7-1500 controllers
into the system as well, so that we can also use our own power generation for
efficiency and cost reasons. The same applies to water consumption. And, of course,
additional machines are continually being integrated into the energy management
system.”

 New machines or measuring

points can
easily be integrated into Energy
Manager so that we can easily
expand
the system.
Jürgen Röck, Deputy Head of Maintenance for
Buildings and Systems, GARDENA Gerstetten

The advantages

Greater convenience, more options

As far as Jürgen Röck is concerned, the SIMATIC Energy Management system has already
proved its worth. The new system can display the data for specific target groups on
clearly designed dashboards, it has sufficient reserves for upcoming tasks, and it can be
adapted and expanded conveniently and flexibly by Jürgen Röck and his team.

The system delivers numerous additional opportunities

for further optimizing energy consumption.

One part of the project at GARDENA involves implementing the acquisition

Production workers can also view the data from the energy
management system
of operating data by means of the SIMATIC S7-1500 controllers. The
company can then quite easily link the energy consumption to production
data, and from this information it can derive key performance indicators
for productivity and energy efficiency. But the analysis of consumption
data over longer periods can also be of great interest. Take the example of
compressed air supply. Here the company can detect leakages based on
trend data – including a cost-benefit calculation, as Jürgen Röck explains:
“How widely did the consumption deviate from regular demand, what did
the leak repair cost us, and how much electric power is this now saving? I
can now visualize this information in the energy management system. One
click and I have the data.”

 “Consumption
efficiency,
data, key figures on productivity and energy

cost-benefit calculations: one click and I have the data.”

 Jürgen Röck, Deputy Head of Maintenance for Buildings and Systems, GARDENA Search for ...
  
Gerstetten

Consumption data on clearly laid-out dashboards Easy to configure and expand

GARDENA currently records the consumption of heat and electrical
energy. “We can make the latest data available to our on-site
controlling at any time in the form of a dashboard – fully automatically
and without having to read any meters. That saves us a lot of work,”
says Jürgen Röck. “The data are stored and backed up in one
standardized database so we can use them at any time for analyses.
And last but not least, we have the possibility of easy access to the
system via a web client – even while we’re out and about. This is a real
benefit for our maintenance team: I can generate alarms, I can send a
notification, and I can log in to the system via secure access using a
browser from any location to check what malfunction is present,
without the need for a computer with a special program.”
GARDENA can manage as many as 50 machines via a single controller.
This gives Jürgen Röck and his team sufficient capacity to easily
integrate new loads into the system. “This flexibility is important, as we
are continuously expanding and updating our production system,” he
says. “In addition, this means we can not only integrate new machines
but also integrate our existing machines into the system on a step-by-
step basis.” Another advantage for Jürgen Röck is that he can configure
the energy management system in a familiar environment: “TIA Portal
provides us with an environment that we are already familiar with –
and thanks to the Energy Suite, we can easily incorporate new
measuring points using a standardized process. Any colleague who is
familiar with TIA Portal is therefore also able to work with the energy
management system. This simplifies the maintenance of the solution.”

Portfolio

Systematic and integrated energy management

At GARDENA, the individual components of SIMATIC Energy Management demonstrate
what perfect interaction looks like. SIMATIC Energy Manager visualizes the latest
consumption data and energy flows, while the SIMATIC Energy Suite and SIMATIC
WinCC Professional support efficient engineering of the solution.

SIMATIC WinCC SIMATIC Energy Manager SIMATIC Energy Suite

SIMATIC SCADA systems: The right The company-wide energy manage- Energy transparency in production
system for any application in any in- ment system for industry, certified in with SIMATIC Energy Suite – simple
dustry.  accordance with ISO 50001.  and integrated. 

References
Intelligent energy management in industry
SIMATIC Energy Management has long since proven itself in actual practice. These
software solutions have been successfully implemented by prestigious companies
around the world in a wide range of industries to meet statutory regulations and DIN EN
ISO 50001 requirements and sustainably lower their energy consumption and costs. You
too can ensure a competitive edge for your company through energy-optimized
operations control.
Bette gmbH & Co. KG |
Bathroom fixtures manufacturer
Elegant design, efficient
production
• Numerous energy flows and
consumers had to be integrated
into a shared energy
management
• Complex key performance
indicators due to very customer-
oriented production
• The results:
- Easy integration of hardware,
easy engineering thanks to block
concept and need-based support
- Detailed and clear analysis of
consumption data and key
performance indicators
- Data hub for key performance
indicators and data for any
component with multiple options
for expansion
 Learn more
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Alfred Ritter GmbH & Co. KG | GF Automotive |Automotive supplier
Chocolate manufacturer Efficient lightweight
Quality. Efficiency. Squared construction – less energy
• RITTER SPORT was looking for a for die casting
modern solution to energy
• GF Automotive opted for a
management, not only to meet
coherent overall concept from
ISO 50001 requirements, but
the field level to the
also to track down hidden
management level. 
potential in the production.
• Distributed, automatic energy
• With Simatic Energy Manager
data acquisition with SIMATIC ET
PRO from Siemens, RITTER SPORT
has found a solution that meets
200SP Energy Meter. 
• The results:
all the necessary criteria. The
system records production data - Ensured DIN EN ISO 50001-
as well as energy data from the certified energy management
Desigo Insight building proces
management system. - Verification of the energy
efficiency potential of the
• The results:
machinery
- A detailed insight into energy
- Tracking and implementation of
and production data
savings measures (e.g. 4,500 m³
- Easy and intuitive dashboards
of compressed air/WE, 10% CO₂
from the energy and production
emissions/5 years)
data
- The possibility of making
information available, not only
on tablet PCs and terminals in the
production area, but also on
mobile terminals
 Learn more  Learn more
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