Open to energy saving ideas

Sustainability and energy efficiency are driving new product developments for the handling and storage industry. Here, Hörmann explains the thinking behind some of its recent door developments

As more and more companies target their supply chain as an area to improve their carbon footprint, new products and designs are being created to add to both operational and efficiency energy consumption. As a leading manufacturer of industrial doors and loading bay equipment, Hörmann is at the forefront of change with new products being developed and new ideas explored.

The company reports an increase in the use of fast action doors to partition existing buildings, in order to maintain temperatures and minimise draughts. These energy saving benefits have also led to greater use of such doors on conveyor systems, where they offer the added benefit of noise reduction. This has led to the introduction of specific doors for conveyor systems but has also accelerated the need for better, more integrated safety systems as having more doors increases the risk of potential collisions with lift trucks and pedestrians.

Doors that can withstand impact and 'repair' themselves by simply relocating, and leading edge safety devices that detect obstructions are widely available and present the operator with a number of choices.

However leading edge devices can be damaged and those that rely on battery power need to be monitored closely, to ensure they are working. These concerns have led to the development of integrated solid state systems, such as Hörmann's Light Grille, that monitors the door opening to a height of 2.5m and automatically halts door travel, if any of the array of light beams are broken.With no moving parts, maintenance is minimal and collision damage unlikely, as the device is contained within the door frame.

In a warehouse the loading bay area can be critical to energy usage.Minimising the time doors are open and increasing insulation in this area can add up to significant cost benefits. An obvious development is better, thicker insulation, but less obvious is identifying the design options and developments that can add value in terms of savings and improving operational efficiency.

Simple design considerations when refurbishing existing loading bays or developing new ones can save energy and reduce your carbon footprint. Techniques developed for cold storage are now being applied to all loading bays. A good example is designing the bay so an insulated door closes in front of a dock leveller, preventing the steel from acting as a thermal bridge.

This requires a dock leveller with a telescopic lip and demonstrates that all the key elements are interlinked.

This technique was used for all 40 loading bays on a new 222,000ft2 distribution centre for organic food retailer Alnatura, in what was a project for the German Sustainability Council. The development relies on renewable energy sources to heat and cool the building, hence the loading bays are critical. As well as the door design, cushion dock seals on the exterior create a seal between containers and the building, that keeps out cold winter and hot summer air.

An additional energy saving measure is the inclusion of double glazed panels in the insulated doors. These allow in natural light, reducing the need for powered light sources, yet maintain the high level of insulation the door provides.

With new products and new thinking being applied, Hörmann has developed a free, on-line, modular planning tool, the Energy Saving Compass. This guide examines the key aspects of energy saving that can be affected by industrial door systems and loading technology solutions. The six themed modules give examples of well-planned loading bays and the options available, as well as an energy loss calculator. Not only is it possible to assess potential savings but the projected pay back time for any investment can also be calculated: www.hormann.co.uk (click the link on the welcome page).

Overall the demand for better energy efficiency will continue to drive the development of new solutions, whether this is through equipment or working practices.

Good planning will maximise the benefits available, as more integrated systems can add to safety and also reduce the number of components that need to be maintained and managed. For the warehouse operator and developer, accessing high quality advice at the planning stage whether for refurbishment or a new development is going to pay dividends in the long term.