Revolutionizing Pump Efficiency for Mercedes Benz
DWS GmbH & Co. KG, a leader in pump repair and optimization, completed a groundbreaking project with Mercedes Benz that aimed to significantly reduce energy consumption through innovative pump technology.
The Company: DWS GmbH & Co. KG
Founded in December 2004 by Frank Woltersdorf, Thomas Neumann, and Ralf Jäger, DWS GmbH & Co. KG has grown from a small company into a prominent player in the pump technology sector. Starting with just three employees in a leased facility in Waßmannsdorf, the company now operates from multiple locations across Germany, including Hannover, Bremen, Kassel, and soon Greifswald. With a consistent increase in turnover, reaching €6.0 million in 2023, DWS continues to expand its services and capabilities.
Comprehensive Services
DWS specializes in:
- Repair and optimization of pumps
- Conversion of pumps to improved mechanical seal systems
- Coating of pumps to reduce friction and wear
- Repair and optimization of hydraulic cylinders
- Repair of gearboxes
Their philosophy, “People who always do what they have always done, will always get what they have always had,” drives them to provide innovative solutions to industry challenges such as security, availability, and environmental impact.
The “Pumpenoffensiv” Project with Mercedes Benz
In 2014, DWS GmbH & Co. KG embarked on the “Pumpenoffensiv” project with Mercedes Benz at the Ludwigsfelde plant. The goal was to reduce energy consumption by addressing friction within pump systems. This initiative began when a pump in the paint shop was disassembled for maintenance, revealing significant surface deterioration due to the transport of abrasive and corrosive fluids.
DWS applied a two-component ceramic-reinforced composite material to combat this issue to the pump components. This coating provided:
- Extraordinarily smooth and durable surfaces
- Significantly reducing friction resistance
- Energy consumption
The success of the “Pumpenoffensiv” project can be attributed to the advanced technology and materials used by DWS.
Achievements and Impact
The pilot test was highly successful, leading to the coating of additional pumps throughout the plant. Highlights of the project’s impact include:
- Coating of 42 pumps, with nine more planned
- Up to 17% reduction in energy consumption for the best-performing pumps
- Annual energy savings of approximately 21,675 kWh, equivalent to the power consumption of five four-person households in Germany
- Return on investment achieved within three months due to reduced maintenance costs and extended pump operation times
Technical Details and Benefits
The success of the “Pumpenoffensiv” project can be attributed to the advanced technology and materials used by DWS:
- Ceramic-Reinforced Composite Material: This two-component coating provides smooth and resistant surfaces, reducing friction within the pump.
- Enhanced Efficiency: The improved surface reduces energy consumption by requiring less power to achieve the same performance.
- Extended Lifespan: The durable coating leads to longer intervals between maintenance, reducing downtime and operational costs.
DWS GmbH & Co. KG’s innovative solutions and strategic growth have established them as a key player in the pump technology sector. The successful collaboration with Mercedes Benz is a testament to their expertise.
The “Pumpenoffensiv” project highlights DWS’s technical capabilities and underscores their commitment to sustainability and energy efficiency, making them a valuable partner for industries looking to reduce their environmental footprint.