Swiss sugar is becoming more sustainable: from the beginning of 2021, the newly built wood-fired thermal power station in Aarberg / CH will supply renewable energy for the sugar factory located there. The handling of the transport logistics will be fully automated and comes from the Austrian high-tech company BERTHOLD.

The wood power plant in Aarberg / CH relies on fully automated handling of transport logistics.
Image: WSP W. Schefer + Partner Ingenieurbüro AG

The Schweizer Zucker AG, the AG für Abfallverwertung (AVAG) and the Terra Nova GmbH set up a groundbreaking environmental project on the site of the sugar factory in Aarberg: a wood-fired thermal power station is to supply the sugar factory with steam and district heating.

The goals were clear:

  • add_circle_outlineReduction of the CO2 emissions of the sugar factory
  • add_circle_outlineCO2-neutral and sustainable energy supply for the sugar factory
  • add_circle_outlineSupply of the sugar factory with a base load of approx. 50% in the beet campaign
  • add_circle_outlineFull supply of the sugar factory in the thick juice campaign and the interim campaigns
  • add_circle_outlineSynergies through the use of existing infrastructures / operating personnel

    The new combined heat and power plant can recycle around 70,000 tons of waste wood per year. With this investment of around CHF 95 million, the Aarberg sugar factory can save around 16,000 tonnes of CO2 annually.

    BERTHOLD as a partner for reliable transport logistics

    Again, it was a successfully implemented reference project that brought those responsible for the topic of “Transport Logistics & Traffic Control System” to BERTHOLD:

    A visit by the planning office WSP W. Schefer + Partner Ingenieurbüro AG, which was commissioned with the HKW planning, to the Renergia waste disposal plant in Perlen / CH was the trigger for a fruitful collaboration:

    Clarity in a short time

    In a very short time – in coordination with the planning office – BERTHOLD was able to present the decision-makers with a clearly formulated concept based on the corresponding tender through to the final offer with a realistic schedule: a flexible and fail-safe system that allows fully automated remote operation.

    It took just 4 ½ months from the first contact to the placing of the order. Despite the tight schedule, at the end of the planning process there was a mature, flexible and efficient solution:

    The tried and tested BLS logistics control system with extensive services developed by BERTHOLD was ultimately the system that was preferred both technically and economically and was commissioned in mid-May 2020.

    Implementation in 2 phases

    In order to enable automation-supported work as quickly as possible despite the current high capacity utilization at BERTHOLD in the Aarberg HKW, this project will be implemented in 2 phases:

    In the first phase, following detailed engineering, the implementation, delivery, installation and commissioning of the BLS logistics control system essentially took place in the basic configuration.

    Individual configurations are made in this phase, reduced to the most essential application-specific requirements.

    This means that remote automation-supported work is possible, even if not all process steps can yet be operated fully automatically.


    Intensive tests with real data, detailed staff training and trial operation round off phase 1 and ensure a smooth start of the Aarberg HKW to the planned full operation at the beginning of 2021.

    In a second phase, the BLS logistics control system is supplemented with all other functionalities, layouts, interfaces and open points are processed until the contract is fully fulfilled.

    The tight schedule is adhered to

    The tested hardware was delivered as planned in September 2020 and the assembly work and the first part of the commissioning on site began without delay. From the current perspective, the actual BLS operation of phase 1 is therefore expected to take place in November 2020.

    Total project scope

    Every BLS logistics control system is individually designed to meet the requirements and processes of the user. This is also the case for the Aarberg HKW:

    Hardware

    • 2 BLS terminals for self-service
    • weighing evaluation
    • IT centre in redundant design
    • traffic control technology

      Software

      • BLS software including configuration
      • interface design for gates, cranes and traffic control systems

        Services

        • Engineering
        • Assembly including cabling
        • Commissioning
        • Startup & training
          The traffic at the single-lane entry and exit is regulated fully automatically.

          Traffic control system for smooth automatic operation

          BERTHOLD is also responsible for the delivery of a traffic control system for smooth operation and the best possible use of the existing traffic areas.

          Together with the customer and the planning office, a traffic concept was worked out as part of the implementation planning, which takes all special features into account:

          The traffic at the single-lane guided entry and exit, at the side entrance and at the truck waiting positions can be controlled safely and fully automatically.

          All required components are part of the BERTHOLD scope of delivery:

          • PLC for the traffic control system
          • Traffic lights at the entrance and waiting position
          • Barriers at the entrance and exit of the weighbridge and at the side or staff access
          • Cameras
          • Induction loops and masts
          • Interface to the gates, the crane and the control technology

            Fully automatic for logistics and disposition

            The BLS logistics control system can also meet the requirements for “remote control”:
            No staff is required on site to handle logistics and dispatching. The system enables fully automatic operation as far as possible. The disposition is carried out remotely from another location.

            Conclusion: Swiss companies rely on BERTHOLD

            BERTHOLD is delighted to be able to implement this exciting project in Aarberg:

            As an Austrian company, to have a solid position in Swiss companies is evidence of smoothly functioning systems, satisfied customers and a good reputation.

            This project proves once again that BERTHOLD can implement projects quickly, clearly and flexibly:

            Thanks to enormous experience, extremely committed employees, excellent and close cooperation with the partners involved and not least due to the modular hardware and software structure of the BLS logistics control system.

            The Swiss Sugar AGSchweizer Zucker AG (SZU) is the only company in Switzerland that processes sugar beet and supplies the Swiss market with sugar and the resulting feed. This gives SZU a market-leading position in terms of quantity, quality and readiness for delivery.

            Terra Nova GmbHAs a Swiss company, Terra Nova GmbH offers “from the garbage can to the socket”
            forward-looking disposal solutions. It is part of the B + T Group, a leading European address for waste recycling. With innovative ideas, residues are put to a meaningful use in efficient and sustainable material and energy cycles.

            AG for waste recycling AVAG – AVAG is the leading regional provider of total disposal, recycling and energy solutions in the Aaare, Gürbe and Emmental valleys as well as in the Bernese Oberland. For around 134 municipalities and their resident companies, it has ensured environmentally friendly, responsible and economical disposal since 1973.

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