We are continually working on reducing our energy consumption. At our Munich plant, we have implemented a number of major projects since 2014 which have made a positive impact in recent years. Further measures have already been kicked off or are being planned for the years ahead.
In recent years, we have already implemented many measures to reduce energy consumption at the Munich location. As part of this, one of the largest projects of 2014 was modernizing the production hall lighting and light control system. For this project, we replaced 1,500 mercury vapor lamps (high-pressure lights) with 1,000 LED overhead and side lights with integrated daylight and presence sensor technology. The intelligently controlled LED technology records movement patterns or daylight intensity, for example, and adjusts the illuminance automatically.
Not only does the company benefit from these measures by saving electricity costs, but employees also enjoy improved light quality and increased work safety. At the same time, CO2 emissions went down by almost 2,000 tons per year. The project was also nominated for the Handelsblatt Energy Award in 2016 for the "Industry" sector due its successful implementation.
Other extensive energy conservation measures that have already been implemented include, for instance, reinforcing the roof insulation and installing new roof hatches in all Munich production halls, a direct digital control system that connects to the building automation system for heating, ventilation, lighting and electrical generation, as well as new well pumps and controls. The ventilation system was equipped with energy-saving motors and cross-flow heat exchangers for heat recovery and a gradual replacement of the windows for better heat insulation has been initiated. In total, more than 700,000 euros have been invested in these energy-saving measures.
Additional projects are planned for the future. For one, energy consumption can be lowered further by purchasing new forced air compressors, which can be aided further through a deliberate approach and adaptation of the application parameters. In another project, we intend to modernize the ventilation system and the control system of the cafeteria.
In 2017, we hope to make a larger purchase and change the district heat supply in Munich over from the four current boilers, which are heated with gas and heating oil, to a block-type thermal power station (BTTP) with an electrical and thermal capacity of 1,000 kWh. In addition to heat, electricity is generated simultaneously in a BTTP. By using energy to generate electricity and heat, utilization rates of more than 90 percent can be reached. At the same time, a BTTP is preferably operated at the site of heat consumption. Due to the short distance, hardly any energy is lost and efficiency increases. We expect a reduction of CO2 emissions of 4,000 tons in a year thanks to the commissioning of the BTTP.
The figures for electricity and gas consumption since 2010 show us that we are on the right path with the conservation measures carried out in recent years. It is because of this that gas consumption could be reduced by more than half at all locations of the GmbH (KMT) from 2010 (86 million kWh) to 2015 (35 million kWh). Power consumption was reduced by about 9.6 million kWh from 2010 to 2015.