© VDI ZRE

The Competence Center for Resource Efficiency offers on behalf of the German Federal Ministry for the Environment, Nature Conservation, Nuclear Safety and Consumer Protection technical know-how for an efficient use of materials and energy in companies.

Our Publications

Studies

Ecological and economic Assessment of Resource Use: Water-miscible cooling Lubricants

Cooling lubricants (coolants) are of great importance in metal cutting and forming. They increase the productivity and cost-effectiveness of the processes. In companies in the metalworking industry, water-miscible cooling lubricants are used in around 90 % of machining processes. They consist of a mostly mineral oil-based base oil and an additive package.

  • Studies
Das Bild zeigt die Anwendung eines Kühlschmierstoffs an einer Produktionsmaschine.© Kadmy/Fotolia.com

Resource Efficiency through Industry 4.0 – Potential for SMEs in the Manufacturing Sector

The digital transformation in industrial production offers considerable potential for increasing material and energy efficiency in companies. At the same time, the digitisation technologies used also require resources themselves: materials, including critical raw material, are used in the production of ICT components. Furthermore, the digital transformation can lead to higher energy consumption. The study "Resource efficiency through industry 4.0 - Potentials for SMEs in the manufacturing sector" focuses on this conflict between opportunities and challenges.

  • Studies
Das Bild zeigt eine Mindmap, in deren Mitte 4.0 zu lesen ist. An den Enden der Arme sind verschiedene Icons zu sehen, die für industrielle Produktion stehen.© VDI ZRE

Tools to discover

Online tools for more resource efficiency: Reducing material and energy consumption helps to cut costs and make businesses more competitive. The following tools help companies to identify their potential for resource efficiency and how to realise it.

  • Cost Calculator
    • Cost Structure Calculator

      This module allows you to display the cost structure in your own company. Users are shown which areas in the company are key cost factors and what proportion of the company's costs are accounted for by material and energy costs. In addition, the operational cost structure can be compared with the respective industry averages.

      Cost Structure Calculatore
    • Material Flow Cost Calculator

      This module provides an introduction to the detailed material and energy flow-based evaluation of production processes based on the DIN EN ISO 14051 standard. The calculator provides support through a structured input option and a graphical representation of the production process. By quantifying loss costs, material and energy consumption can be localized within the company.

      Material Flow Cost Calculator
    • Investment Calculator

      With this module, investments can be compared on the basis of life cycle costs. The amortization periods of various new investment alternatives can be clearly calculated. The basis for this is the dynamic amortization calculation. The inputs for the amortization calculation are based on the VDMA standard sheet 34160.

      Investment Calculator
  • Resource Checks
    • Base Module

      Learn how to reduce material losses caused by rework in production, as well as how to lower your overall energy consumption.

      Base Module
    • Foundry Technology

      In order to save material and energy, it is worth taking a look at the energy-intensive melting process, for example, the scrap rate or the amount of waste.

      Foundry Technology
    • Injection Moulding

      Reduce your material and energy consumption by reducing scrap and rework rates or through downtime management. Get to know the advantages.

      Injection Moulding
    • Extrusion

      Material and energy can also be saved in the extrusion process. The resource check shows ways in which energy and material can be saved.

      Extrusion
    • Deep-Drawing

      Deep drawing is a very resource-intensive process. Identify potential savings in your process. There are many ways to reduce the use of resources.

      Deep-Drawing
    • Cold-Rolling

      Cold-Rolling is a classic forming process with central work steps such as pickling, pre-rolling, heating and re-rolling. The resource check shows starting points for reducing energy and material.

      Cold-Rolling
    • Hot-Rolling

      Hot-Rolling is a classic forming process with central work steps such as fettling, heating, scaling and rolling mill. The resource check shows starting points for reducing energy and material.

      Hot-Rolling
    • Machining

      Machining is a central and widely used production process in the manufacturing industry. Numerous measures make it possible to reduce the consumption of materials and energy.

      Machining
    • Electroplating

      The Resource Check Electroplating shows many starting points for saving material and energy, e.g. by recycling production aids.

      Electroplating
    • Paint

      The application methods and types of coatings used are diverse. Find out about the many possibilities for saving material and energy in the coating process.

      Paint
    • Printed Circuit Technology

      The resource check for printed circuit technology provides companies with an overview of optimisation measures in the production process in order to save material and energy.

      Printed Circuit Technology
    • Metal Working

      Do you know measures and methods to increase resource efficiency in metal processing? Complete the resource check and learn about measures to avoid scrap or save energy.

      Metal Working
    • Fine Chemicals

      Can you save energy and materials in the production of fine chemicals? Take the resource check. Learn about numerous strategies and measures to reduce resource consumption in your production.

      Fine Chemicals
    • Lifts

      The resource check shows potential for energy efficiency in connection with elevators. In older buildings in particular, elevators can account for a significant share of total energy consumption.

      Lifts
    • Water Management

      With this resource check, you can identify opportunities to reduce your water consumption in and around the building. Once you have answered all the questions, the evaluation will show you possible resource efficiency potential in connection with your building(s).

      Water Management
    • Hospital: Benchmark Consumption Quantity

      This resource check will tell you how your hospital performs in comparison in terms of heating energy demand, electricity demand and water demand.

      Hospital: Benchmark Consumption Quantity
    • Hospital: Facility Management

      The resource check helps you identify resource efficiency potential in hospital facility management.

      Hospital: Facility Management
    • Hospital: Energetic Renovation

      Find out with this resource check which energy refurbishments should be carried out to sustainably reduce resource consumption in the hospital. Once you have answered all the questions, the evaluation will show you possible resource efficiency potential in connection with your building or buildings.

      Hospital: Energetic Renovation
  • Process Chains
    • Electroplating

      The electroplating process chain illustrates best available techniques for the process steps before and after metal deposition as well as successful project examples. Videos on the recycling of production aids show how resource efficiency can be implemented in electroplating.

      Electroplating
  • Cost Structure Calculator

    This module allows you to display the cost structure in your own company. Users are shown which areas in the company are key cost factors and what proportion of the company's costs are accounted for by material and energy costs. In addition, the operational cost structure can be compared with the respective industry averages.

    Cost Structure Calculatore
  • Material Flow Cost Calculator

    This module provides an introduction to the detailed material and energy flow-based evaluation of production processes based on the DIN EN ISO 14051 standard. The calculator provides support through a structured input option and a graphical representation of the production process. By quantifying loss costs, material and energy consumption can be localized within the company.

    Material Flow Cost Calculator
  • Investment Calculator

    With this module, investments can be compared on the basis of life cycle costs. The amortization periods of various new investment alternatives can be clearly calculated. The basis for this is the dynamic amortization calculation. The inputs for the amortization calculation are based on the VDMA standard sheet 34160.

    Investment Calculator
  • Base Module

    Learn how to reduce material losses caused by rework in production, as well as how to lower your overall energy consumption.

    Base Module
  • Foundry Technology

    In order to save material and energy, it is worth taking a look at the energy-intensive melting process, for example, the scrap rate or the amount of waste.

    Foundry Technology
  • Injection Moulding

    Reduce your material and energy consumption by reducing scrap and rework rates or through downtime management. Get to know the advantages.

    Injection Moulding
  • Extrusion

    Material and energy can also be saved in the extrusion process. The resource check shows ways in which energy and material can be saved.

    Extrusion
  • Deep-Drawing

    Deep drawing is a very resource-intensive process. Identify potential savings in your process. There are many ways to reduce the use of resources.

    Deep-Drawing
  • Cold-Rolling

    Cold-Rolling is a classic forming process with central work steps such as pickling, pre-rolling, heating and re-rolling. The resource check shows starting points for reducing energy and material.

    Cold-Rolling
  • Hot-Rolling

    Hot-Rolling is a classic forming process with central work steps such as fettling, heating, scaling and rolling mill. The resource check shows starting points for reducing energy and material.

    Hot-Rolling
  • Machining

    Machining is a central and widely used production process in the manufacturing industry. Numerous measures make it possible to reduce the consumption of materials and energy.

    Machining
  • Electroplating

    The Resource Check Electroplating shows many starting points for saving material and energy, e.g. by recycling production aids.

    Electroplating
  • Paint

    The application methods and types of coatings used are diverse. Find out about the many possibilities for saving material and energy in the coating process.

    Paint
  • Printed Circuit Technology

    The resource check for printed circuit technology provides companies with an overview of optimisation measures in the production process in order to save material and energy.

    Printed Circuit Technology
  • Metal Working

    Do you know measures and methods to increase resource efficiency in metal processing? Complete the resource check and learn about measures to avoid scrap or save energy.

    Metal Working
  • Fine Chemicals

    Can you save energy and materials in the production of fine chemicals? Take the resource check. Learn about numerous strategies and measures to reduce resource consumption in your production.

    Fine Chemicals
  • Lifts

    The resource check shows potential for energy efficiency in connection with elevators. In older buildings in particular, elevators can account for a significant share of total energy consumption.

    Lifts
  • Water Management

    With this resource check, you can identify opportunities to reduce your water consumption in and around the building. Once you have answered all the questions, the evaluation will show you possible resource efficiency potential in connection with your building(s).

    Water Management
  • Hospital: Benchmark Consumption Quantity

    This resource check will tell you how your hospital performs in comparison in terms of heating energy demand, electricity demand and water demand.

    Hospital: Benchmark Consumption Quantity
  • Hospital: Facility Management

    The resource check helps you identify resource efficiency potential in hospital facility management.

    Hospital: Facility Management
  • Hospital: Energetic Renovation

    Find out with this resource check which energy refurbishments should be carried out to sustainably reduce resource consumption in the hospital. Once you have answered all the questions, the evaluation will show you possible resource efficiency potential in connection with your building or buildings.

    Hospital: Energetic Renovation
  • Electroplating

    The electroplating process chain illustrates best available techniques for the process steps before and after metal deposition as well as successful project examples. Videos on the recycling of production aids show how resource efficiency can be implemented in electroplating.

    Electroplating

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