Assessing the status quo<\/strong><\/h4>\nIn the first step, we identify all individual measures for process optimization. These include improving the efficiency of electrical consumers such as fans, motors, and lighting, as well as process engineering adjustments \u2013 for example, lowering process temperatures or making fundamental changes to the workflow. This creates a solid foundation for further planning.<\/p>\n\n\n\n
Key: the “pinch” analysis<\/strong><\/h4>\nThe “pinch” analysis is a key tool for process integration. It enables us to identify efficient and cost-effective concepts for direct heat recovery or the use of heat pumps. The goal of a “pinch” analysis is to optimally connect heat sources and sinks via heat exchangers in order to utilize waste heat internally. Crucial to this is the cascaded use of waste heat according to temperature levels: waste heat is always utilized at the highest possible temperature level to fully exploit its energy potential. The result of the “pinch” analysis is an overview of how heating and cooling demands can be optimally coupled.<\/p>\n
Based on the analysis, technologies such as solar thermal, combined heat and power, heat pumps, or thermal storage can be integrated into a model. This allows our customers to identify which heating and cooling demands need to be considered and which integration points are suitable for heat pumps and storage systems. Additionally, the effects of individual measures on total energy demand become apparent. With a systematic “pinch” analysis, energy efficiency can be increased to the point where up to 40% of energy can be saved.<\/p>\n\n\n\n
Simulate operating strategies and component design<\/strong><\/h4>\nUsing dynamic simulation, we realistically model temporal fluctuations in loads, generators, and storage systems. This allows for the precise sizing of process heating and cooling systems, providing investment security for companies and avoiding over- or undersizing. Various operating strategies can also be simulated, for instance, in response to production changes or new temperature requirements. The \u201cColSim\u201d simulation tool we developed at Fraunhofer ISE is specifically designed for such dynamic analyses.<\/p>\n\n\n\n
Optimizing the energy supply<\/strong><\/h4>\nIn the final step, we further develop the heating and cooling demand system \u2013 which has been optimized through “pinch” analysis and simulation \u2013 using energy system analysis. In doing so, we incorporate all available energy sources (electricity, hydrogen, biomass, natural gas) as well as various technologies (e.g., photovoltaics, combined heat and power, power-to-heat, solar thermal, battery storage) and time-varying energy prices. It is crucial to consider energy carrier prices and availability in order to create a long-term sustainable transformation plan. For this task, we have access to the Fraunhofer ISE tool \u201cDistrict<\/a>\u201d.<\/p>\n\n\n\nExamples<\/strong><\/h4>\nKoehler Paper<\/em><\/p>\nAt Koehler Paper\u2019s Kehl site, we were able to identify ways to drastically reduce natural gas consumption. In doing so, we identified optimization potential for the entire property, including paper machines and the on-site power plant. We also examined the potential connection to a district heating network, enabling us to develop concepts for steam generation using heat pumps in addition to heat recovery with heat exchangers.<\/p>\n\n\n\n![\"\"](\"https:\/\/blog.innovation4e.de\/wp-content\/uploads\/2026\/06\/Luftbild-Kehl-650x433.jpg\")
<\/a>\u00a9 Koehler Press Picture<\/figcaption><\/figure>\n\n\n\nAdelholzener Alpenquellen GmbH<\/em><\/p>\nFor Adelholzener Alpenquellen GmbH, we developed a concept that enables the complete elimination of energy-related CO\u2082 emissions. In addition to improved direct heat recovery, we integrated industrial heat pumps. Key elements include the use of waste heat from the refrigeration system and wastewater with large-scale heat pumps, the optimization of internal heat recovery, and the use of thermal storage.<\/p>\n
Our work demonstrates that “pinch” analysis is ideally suited for identifying measures to reduce CO\u2082 emissions for heating and cooling in industry. Combined with dynamic process simulation and energy system modeling, it enables the development and evaluation of concepts for technologies such as heat pumps, solar thermal systems, thermal storage, and CHP plants \u2013 always taking technical and economic aspects into account.<\/p>\n\n\n\n
At Fraunhofer ISE, we develop innovative solutions to support the transition towards a climate-neutral industry. Our research focuses on the integration of renewable energies, the improvement of energy efficiency and the use of waste heat in industrial processes. By combining technological development, process optimization, and comprehensive consulting, we help companies reduce their emissions and make their production processes future-proof.<\/p>\n\n\n\n
The “pinch” analysis is a key tool for process integration. It enables us to identify efficient and cost-effective concepts for direct heat recovery or the use of heat pumps. The goal of a “pinch” analysis is to optimally connect heat sources and sinks via heat exchangers in order to utilize waste heat internally. Crucial to this is the cascaded use of waste heat according to temperature levels: waste heat is always utilized at the highest possible temperature level to fully exploit its energy potential. The result of the “pinch” analysis is an overview of how heating and cooling demands can be optimally coupled.<\/p>\n
Based on the analysis, technologies such as solar thermal, combined heat and power, heat pumps, or thermal storage can be integrated into a model. This allows our customers to identify which heating and cooling demands need to be considered and which integration points are suitable for heat pumps and storage systems. Additionally, the effects of individual measures on total energy demand become apparent. With a systematic “pinch” analysis, energy efficiency can be increased to the point where up to 40% of energy can be saved.<\/p>\n\n\n\n
Simulate operating strategies and component design<\/strong><\/h4>\nUsing dynamic simulation, we realistically model temporal fluctuations in loads, generators, and storage systems. This allows for the precise sizing of process heating and cooling systems, providing investment security for companies and avoiding over- or undersizing. Various operating strategies can also be simulated, for instance, in response to production changes or new temperature requirements. The \u201cColSim\u201d simulation tool we developed at Fraunhofer ISE is specifically designed for such dynamic analyses.<\/p>\n\n\n\n
Optimizing the energy supply<\/strong><\/h4>\nIn the final step, we further develop the heating and cooling demand system \u2013 which has been optimized through “pinch” analysis and simulation \u2013 using energy system analysis. In doing so, we incorporate all available energy sources (electricity, hydrogen, biomass, natural gas) as well as various technologies (e.g., photovoltaics, combined heat and power, power-to-heat, solar thermal, battery storage) and time-varying energy prices. It is crucial to consider energy carrier prices and availability in order to create a long-term sustainable transformation plan. For this task, we have access to the Fraunhofer ISE tool \u201cDistrict<\/a>\u201d.<\/p>\n\n\n\nExamples<\/strong><\/h4>\nKoehler Paper<\/em><\/p>\nAt Koehler Paper\u2019s Kehl site, we were able to identify ways to drastically reduce natural gas consumption. In doing so, we identified optimization potential for the entire property, including paper machines and the on-site power plant. We also examined the potential connection to a district heating network, enabling us to develop concepts for steam generation using heat pumps in addition to heat recovery with heat exchangers.<\/p>\n\n\n\n<\/a>\u00a9 Koehler Press Picture<\/figcaption><\/figure>\n\n\n\nAdelholzener Alpenquellen GmbH<\/em><\/p>\nFor Adelholzener Alpenquellen GmbH, we developed a concept that enables the complete elimination of energy-related CO\u2082 emissions. In addition to improved direct heat recovery, we integrated industrial heat pumps. Key elements include the use of waste heat from the refrigeration system and wastewater with large-scale heat pumps, the optimization of internal heat recovery, and the use of thermal storage.<\/p>\n
Our work demonstrates that “pinch” analysis is ideally suited for identifying measures to reduce CO\u2082 emissions for heating and cooling in industry. Combined with dynamic process simulation and energy system modeling, it enables the development and evaluation of concepts for technologies such as heat pumps, solar thermal systems, thermal storage, and CHP plants \u2013 always taking technical and economic aspects into account.<\/p>\n\n\n\n
At Fraunhofer ISE, we develop innovative solutions to support the transition towards a climate-neutral industry. Our research focuses on the integration of renewable energies, the improvement of energy efficiency and the use of waste heat in industrial processes. By combining technological development, process optimization, and comprehensive consulting, we help companies reduce their emissions and make their production processes future-proof.<\/p>\n\n\n\n
In the final step, we further develop the heating and cooling demand system \u2013 which has been optimized through “pinch” analysis and simulation \u2013 using energy system analysis. In doing so, we incorporate all available energy sources (electricity, hydrogen, biomass, natural gas) as well as various technologies (e.g., photovoltaics, combined heat and power, power-to-heat, solar thermal, battery storage) and time-varying energy prices. It is crucial to consider energy carrier prices and availability in order to create a long-term sustainable transformation plan. For this task, we have access to the Fraunhofer ISE tool \u201cDistrict<\/a>\u201d.<\/p>\n\n\n\n Koehler Paper<\/em><\/p>\n At Koehler Paper\u2019s Kehl site, we were able to identify ways to drastically reduce natural gas consumption. In doing so, we identified optimization potential for the entire property, including paper machines and the on-site power plant. We also examined the potential connection to a district heating network, enabling us to develop concepts for steam generation using heat pumps in addition to heat recovery with heat exchangers.<\/p>\n\n\n\n Adelholzener Alpenquellen GmbH<\/em><\/p>\n For Adelholzener Alpenquellen GmbH, we developed a concept that enables the complete elimination of energy-related CO\u2082 emissions. In addition to improved direct heat recovery, we integrated industrial heat pumps. Key elements include the use of waste heat from the refrigeration system and wastewater with large-scale heat pumps, the optimization of internal heat recovery, and the use of thermal storage.<\/p>\n Our work demonstrates that “pinch” analysis is ideally suited for identifying measures to reduce CO\u2082 emissions for heating and cooling in industry. Combined with dynamic process simulation and energy system modeling, it enables the development and evaluation of concepts for technologies such as heat pumps, solar thermal systems, thermal storage, and CHP plants \u2013 always taking technical and economic aspects into account.<\/p>\n\n\n\n At Fraunhofer ISE, we develop innovative solutions to support the transition towards a climate-neutral industry. Our research focuses on the integration of renewable energies, the improvement of energy efficiency and the use of waste heat in industrial processes. By combining technological development, process optimization, and comprehensive consulting, we help companies reduce their emissions and make their production processes future-proof.<\/p>\n\n\n\nExamples<\/strong><\/h4>\n
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