DIS/CREADIS

INSIGHTS

ADDRESSING 
HIGH MAINTENANCE COSTS 
IN RENEWABLE ENERGY

In the renewable energy sector, high maintenance costs are a growing concern. As infrastructure such as wind turbines age, they demand more maintenance, leading to increased operating costs. This challenge is compounded by the need for specialized maintenance skills and technologies. Owner-operators are increasingly considering the self-perform model to gain control over costs and operational demands.

 

The self-performing model means that the owner-operators retain responsibility for the component risk and are ultimately responsible for carrying out their inspections, maintenance, and repairs on turbines or wind farms. By conducting regular inspections and identifying issues before they become more significant, owner-operators reduce the risk of more costly repairs and downtime in the long run, as well as extending the lifespan of turbines, reducing the need for replacements.

Owner-operator Strategies for Reducing Maintenance Costs

Predictive Maintenance: Utilizing data analytics and sensor technology to predict when maintenance is required can significantly reduce downtime and extend asset life. This approach moves away from routine schedules to maintenance based on actual need.

 

Remote Monitoring and Incident Management: Implementing remote monitoring systems helps in early detection of potential issues. Efficient incident management can minimize downtime and optimize repair processes.

 

Quality Assurance and Regular Inspections: Regular inspections and rigorous quality assurance processes ensure that equipment operates efficiently, and malfunctions are caught early.

 

Optimized Maintenance Operations: Streamlining maintenance processes and employing skilled technicians can enhance operational efficiency. Effective resource management and the use of advanced tools and methods can further reduce costs.

 

Long-Term Asset Strategy: Developing a long-term strategy for asset management, including considerations for repowering, or upgrading older installations, can help in balancing costs and efficiency.

 

 

A Path to Lower Costs and Enhanced Efficiency

Tackling high maintenance costs requires a multi-faceted approach. By employing strategies like predictive maintenance, remote monitoring, and a focus on quality and efficiency, owner-operators can reduce costs while ensuring the longevity and reliability of their assets.

 

Our approach is centered on predictive maintenance strategies, using advanced data analytics to anticipate maintenance needs. This proactive method reduces unplanned downtime and extends asset life, leading to significant cost savings. Additionally, our expertise in incident management, quality assurance, and lifetime strategy planning ensures that renewable energy assets operate at peak efficiency with minimal interruptions. We can support owner-operators to effectively manage and reduce their maintenance costs, paving the way for more sustainable and economically viable operations.

Learn more about how to manage operational costs and increase profitability through AI and human expertise here.

The Challenge of Maintenance in Renewable Energy

In the renewable energy sector, high maintenance costs are a growing concern. As infrastructure such as wind turbines age, they demand more maintenance, leading to increased operating costs. This challenge is compounded by the need for specialized maintenance skills and technologies. Owner-operators are increasingly considering the self-perform model to gain control over costs and operational demands.

 

The self-performing model means that the owner-operators retain responsibility for the component risk and are ultimately responsible for carrying out their inspections, maintenance, and repairs on turbines or wind farms. By conducting regular inspections and identifying issues before they become more significant, owner-operators reduce the risk of more costly repairs and downtime in the long run, as well as extending the lifespan of turbines, reducing the need for replacements.

Owner-operator Strategies for Reducing Maintenance Costs

 

Predictive Maintenance: Utilizing data analytics and sensor technology to predict when maintenance is required can significantly reduce downtime and extend asset life. This approach moves away from routine schedules to maintenance based on actual need.

 

Remote Monitoring and Incident Management: Implementing remote monitoring systems helps in early detection of potential issues. Efficient incident management can minimize downtime and optimize repair processes.

 

Quality Assurance and Regular Inspections: Regular inspections and rigorous quality assurance processes ensure that equipment operates efficiently, and malfunctions are caught early.

 

Optimized Maintenance Operations: Streamlining maintenance processes and employing skilled technicians can enhance operational efficiency. Effective resource management and the use of advanced tools and methods can further reduce costs.

 

Long-Term Asset Strategy: Developing a long-term strategy for asset management, including considerations for repowering, or upgrading older installations, can help in balancing costs and efficiency.

 

A Path to Lower Costs and Enhanced Efficiency

Tackling high maintenance costs requires a multi-faceted approach. By employing strategies like predictive maintenance, remote monitoring, and a focus on quality and efficiency, owner-operators can reduce costs while ensuring the longevity and reliability of their assets.

 

At DIS/CREADIS our approach is centered on predictive maintenance strategies, using advanced data analytics to anticipate maintenance needs. This proactive method reduces unplanned downtime and extends asset life, leading to significant cost savings. Additionally, our expertise in incident management, quality assurance, and lifetime strategy planning ensures that renewable energy assets operate at peak efficiency with minimal interruptions. We can support owner-operators to effectively manage and reduce their maintenance costs, paving the way for more sustainable and economically viable operations.

 

Learn more about how to manage operational costs and increase profitability through AI and human expertise here

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Solar: Developers & Operators
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Food & Beverage
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Industrial & Consumer Goods
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NILFISK EGHOLM – External development department

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NILFISK-ADVANCE AS – NEO New electronic platform

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NILFISK – Designing a new vacuum cleaner

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JPG BUDOWNICTWO SP Z O. O. – ADVANCED SOLUTION FOR ENHANCED EMISSIONS COMPLIANCE

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J.N. Bech – STREAMLINING PACKAGING PROCESSES FOR GREATER EFFICIENCY AND QUALITY

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Industrial & Consumer Goods
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IR HIREL - DESIGNING RESILIENT POWER SUPPLY CABINETS FOR SPACE

IR HiRel, a division of INFINEON Technologies, specializes in providing power electronics to the space industry. As the space industry has grown over the years, IR HiRel has constantly worked to develop new and innovative power supplies for satellites. The company approached DIS/CREADIS for help in designing and analyzing the power supply cabinets for their latest project.
Industrial & Consumer Goods
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HWAM – INTELLIGENT HEAT SYSTEM FOR WOOD-BURNING STOVES

HWAM, a wood-burning stove company founded in 1973, has been dedicated to creating modern, user-friendly, high-performing, and well-designed wood-burning stoves. In recent years, the company has shifted its focus towards making stoves that are more environmentally friendly and easier to use. To achieve this gal, HWAM has worked with IHS Innovation to develop a new system called IHS (Intelligent Heat System).
Green Fuel & Energy: Developers & Operators
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HALDOR TOPSØE A/S – NECESSARY COMPONENT TO IMPREGNATION MACHINE FOR BRAZILIAN FACTORY EXPANSION

Haldor Topsøe is a globally recognized company in the field of heterogeneous catalysis, which involves catalytic elements such as monoliths, that reduce harmful toxins in internal combustion engines. In an attempt to expand its market share, Haldor Topsøe decided to build a factory in southern Brazil’s Santa Catarina region. The factory would specialize in finalizing untreated monoliths in an impregnation and calcination process, preparing them for delivery. Haldor Topsøe collaborated with DIS/CREADIS to develop a simple production line and impregnation machine specifically for the Brazilian factory.
Green Fuel & Energy: Developers & Operators
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TOPSOE - POWERING PROGRESS

Topsoe is a leading Danish chemical company that specializes in the production of catalysts and technologies for the chemical industry. In 2020, the company made a strategic decision to increase its production capacity by developing a hydrogen processing catalyst plant in Pasadena, Texas, with a target completion date of 2023. The plant will produce products for traditional refining as well as renewable diesel and jet fuel using Topsoe’s HydroFlex™ technology. Topsoe needed a reliable partner to help execute this challenging project within the given timeline.
Industrial & Consumer Goods
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GRUNDFOS – ENERGY-EFFICIENT CONTROL BOX FOR NEXT-GENERATION PUMPS

Grundfos is a leading global pump manufacturer and supplier that helps their customers move, treat and manage water. Founded in 1945, Grundfos has a presence in over 56 countries and employs more than 19,000 people worldwide. Their products and solutions are used in a wide range of applications, including residential, commercial and industrial buildings, water supply, irrigation, industry and mining.
Industrial & Consumer Goods
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GRUNDFOS – DIGITIZING ACCESS TO SAFE WATER

Grundfos is a leading global manufacturer and supplier of pumps and pumping systems, providing solutions to customers in the water supply, manufacturing, food, and beverage, and building services sectors. The company has a strong focus on sustainability and has over 60 years of experience in developing, selling, and servicing pumps.
Medico
Case

GROULEFF DK – PRECISION AND INNOVATION IN MEDICAL EQUIPMENT

Grouleff DK specializes in developing and producing medical equipment and was tasked with delivering a specially designed chair and bed for a MEG (magnetoencephalography) scanner. A MEG scanner maps the magnetic signals of a brain and requires a stable and uninterrupted scan to produce accurate images. Grouleff DK was approached by an English customer to create a chair and a bed in anti-magnetic materials with fine-mechanical solutions to fit their customer’s MEG scanner precisely. As this was the first time Grouleff DK had created a chair and a bed for a MEG scanner, they required external resources to complete the task and turned to DIS/CREADIS for assistance.
Industrial & Consumer Goods
Case

MEKOPRINT – Bus Shelter

Mekoprint is a Danish company that produces and supplies components including micromechanical components, metal solutions, EMI shielding, industrial graphic solutions, and more. They were contacted by JCDecaux Sweden to further develop and produce a bus shelter for the Swedish city of Gävle. However, the project required skills that Mekoprint did not possess. They needed an experienced engineering service provider to complete their project for JCDecaux.
Industrial & Consumer Goods
Case

FLSMIDTH - PARAMETRIC MODELING AND DESIGN SERVICES EMPOWER FLSMIDTH TO DEVELOP A NEXT GENERATION MILL

FLSmidth is an international supplier to the cement industry, and they have been using the OK™ Mill as their standard mill since 1993. However, with the passage of time, they realized the need for an improved and advanced version of the mill to meet the increasing demands of the cement industry. The company initiated a development project to create a new generation of the OK™ Mill. The project included modeling, standardization, cost optimization, and technical improvement of the mill.
Industrial & Consumer Goods
Case

FETTE COMPACTING – UNLOCKING EFFICIENCY AND EXPERTISE

Fette Compacting is a leading producer of machinery for industrial tablet and capsule manufacturing. When they needed to relieve their internal electrical engineering department for a limited period, they contacted DIS/CREADIS. DIS/CREADIS was tasked with reviewing and proofing master plans, preparing production and customer plans, building, and expanding symbol databases, and programming a script for creating an I/O table.
Case

EXRUPTIVE- EXPEDITING AIRPORT SECURITY WITH GROUNDBREAKING X-RAY TECHNOLOGY SOLUTION

Exruptive, a developer of innovative technology solutions, has created a new X-ray technology system that allows for faster, cheaper, and easier security checks at airports. The system is designed to scan carry-on hand luggage in one go, replacing the need for traditional trays at security checks. The company expects the technology to be able to handle up to 600 passengers per hour, a significant increase from the current average of 150 passengers per hour. With approximately 3.5 billion airline passengers traveling worldwide each year, the cost savings potential is significant.
Medico
Case

DENTSPLY SIRONA – REENGINEERING DENTAL IMPLANT PRODUCTION

Dentsply Sirona is a leading provider of dental products and technologies, with a focus on providing innovative solutions for better, safer, and faster dental care. The company produces instruments and dental implants for dentists worldwide and has been operating for over 130 years. To continue to provide high-quality products and remain competitive in the industry, Dentsply Sirona needed to update and automate their production process.
Industrial & Consumer Goods
Case

DANFOSS – ENGINEERING ALTERNATIVE SOLUTIONS FOR DEGREASING

Danfoss is a global leader in providing engineering solutions and technologies. They are committed to delivering innovative, energy-efficient, and sustainable products. The company operates in several industries, including heating, cooling, refrigeration, and industrial automation.
Industrial & Consumer Goods
Case

DANFOSS – COOLING BREAKTHROUGH

Danfoss is a global leader in providing engineering solutions and technologies. They are committed to delivering innovative, energy-efficient, and sustainable products. The company operates in several industries, including heating, cooling, refrigeration, and industrial automation. Danfoss was developing a new frequency converter for controlling the speed of electric motors. In the design phase, simulations needed to be performed on 3D models, where the results would form the basis for the development of the inverters. However, Danfoss lacked the necessary resources to perform the simulations, and so they required assistance from a qualified engineering consulting firm.
Industrial & Consumer Goods
Case

DALI – SONIC BREAKTHROUGH

DALI is a Danish high-fidelity (hi-fi) speaker manufacturer that specializes in designing and manufacturing high-quality speakers for the ultimate audio experience. The company had a new product in the pipeline, the DALI Sound Hub interface box, with wireless communication for speakers and the option for streaming.
Pharma
Case

CP KELCO - UNLOCKING PRODUCT INNOVATION

CP Kelco, part of the US-based J.M. Huber Corporation, is known for producing nature-based ingredients such as carrageenan and pectin that are used to enhance the texture and consistency of food, personal care, and pharmaceutical products. The company was in the process of developing a new product but encountered a challenge when the project plan required more details. To address this issue, CP Kelco asked DIS/CREADIS for assistance in facilitating a three-day workshop that would help update the project plan and establish a common understanding and overview of the project.
Industrial & Consumer Goods
Case

COMET YXLON TEAMS UP WITH DIS/CREADIS TO DEVELOP CUTTING-EDGE X-RAY SYSTEM

Comet Yxlon specializes in industrial X-ray products. Manufacturers in the aerospace, automotive, and electronics industries rely on Comet Yxlon to maximize their product quality and the efficiency of their production. Comet Yxlon received an order for a new X-ray system capable of scanning materials based on their molecular structure. This new system required extreme precision and reproducibility to accurately measure different materials.
Industrial & Consumer Goods
Case

CEMENTOWNIA ODRA S.A. – IMPROVING CLINKER LOGISTICS

Cementownia Odra is a Polish cement manufacturer. They were facing challenges with their clinker delivery process, particularly with the loading and unloading of clinker from trucks. The process was not automated, leading to delays in delivery and increased labor costs. In addition, there were issues with dust emissions during the unloading process, which had to be addressed to comply with environmental regulations. Cementownia Odra needed a solution that would optimize the delivery process, improve efficiency, and limit dust emissions.
Industrial & Consumer Goods
Case

CEMENTOWNIA MALOGOSZCZ – BREAKING BOTTLENECKS

Cementownia Malogoszcz is a cement plant located in Poland and is part of Lafarge. The plant has been operational for 45 years and is known for producing high-quality cement and is constantly looking for ways to improve its processes and increase efficiency.
Industrial & Consumer Goods
Case

CEMENT OZARÓW S.A. – REDUCING DOWNTIME

Cement Ożarów is a CRH company based in central Poland that produces cement, aggregates, and ready-mix concrete. The company’s goal is to provide quality building materials that meet the needs of the construction industry. Cement Ożarów is committed to reducing its environmental impact by reducing carbon dioxide emissions, minimizing the use of natural resources, and increasing its use of alternative fuels.
Industrial & Consumer Goods
Case

B-PLUS AUTOMOTIVE GMBH – ACCELERATING THE ROAD TO AUTONOMY

b-plus Group is an automotive engineering company based in Southern Germany that develops hardware and software solutions for autonomous and automated driving. b-plus specializes in accelerating development cycles and bringing innovative technologies safely into production and onto the road. Their objective is to develop technologies and processes that will facilitate the operation of self-driving vehicles. As part of this effort, they launched the project “Connected Car – Solutions from Sensor to Cloud” to collect and process data through sensors to make the processing more accessible and support the user when generating and analyzing data.
Food & Beverage
Case

ARLA FOODS AMBA – CHEESE PRODUCTION REIMAGINED

Arla Foods is a global dairy company that produces dairy products, including cheese. The company has a strong focus on sustainability, ensuring that their products are made in an environmentally friendly way. To maintain high standards and improve efficiency, Arla Foods enlisted the help of DIS/CREADIS to optimize their cheese mixing process.
Food & Beverage
Case

ARLA FOODS – OPTIMIZING DAIRY PACKAGING

Arla Foods is the world’s fourth largest dairy company and a cooperative owned by more than 12,500 dairy farmers. Arla combines traditional craftsmanship and world-class technologies to ensure its products remain closer to nature, from farm to fridge. Arla Foods Gjesing dairy plant in Denmark produces a variety of cheeses, including the popular ‘Blue Castello’ blue cheese, which is sold domestically and internationally. The plant’s packaging line, which is over a decade old and was originally installed with the help of DIS/CREADIS, has been expanded and modified over the years. Recent changes have made it difficult for the operators to manage the line.
Industrial & Consumer Goods
Case

ALFA LAVAL – COLLABORATIVE EXCELLENCE

Alfa Laval is a leading provider of solutions for heat transfer, separation, and fluid handling technologies for various industries such as energy, food and beverage, marine, pharmaceuticals, and water and wastewater. One of their products is the ORCA series, which are vacuum vapor compression water makers used in offshore facilities to convert saltwater into freshwater. When the ORCA series needed a technical update, Alfa Laval’s R&D team needed to partner with DIS/CREADIS to create a more modern and contemporary design.
Medico
Case

ADVALIGHT – REVITALIZING MEDICAL LASER TECHNOLOGY

Advalight is a Danish company that specializes in the development and manufacturing of medical laser devices. The company was established as a research project at DTU (Technical University of Denmark) 10 years ago, with a focus on laser sources. Since then, Advalight has grown into a company that produces laser devices for treating skin diseases and skin disorders such as chronic redness, spider veins, scars, moles, and acne. Advalight’s medical laser devices use yellow (589nm) and infrared (1319nm) laser lights, which are more effective in treating skin problems compared to other lasers. Advalight’s laser is built on solids (crystals) instead of on gas or coloring, which makes it less expensive, more reliable, and more stable than other medical yellow lasers on the market.
Industrial & Consumer Goods
Case

ACTUATOR SOLUTIONS – ELEVATING LUXURY CAR COMFORT

Actuator Solutions GmbH is a German joint venture between SAES GETTERS and Präzision SE and is the largest manufacturer of Shape Memory Alloy (SMA) actuators for the automotive industry, mobile units, and the pharmaceutical industry. SMA is a group of high-tech materials that can be turned into pre-defined shapes when heated. Actuator Solutions utilize the special features of SMA to develop innovative, compact, energy-saving, and low-noise lightweight actuators for microfluidic and micro-optical drives for all relevant industries. Actuator Solutions have been working with DIS/CREADIS since 2012 to develop different actuators for the automotive industry and for mobile units.
Medico
Case

ABENA– ADVANCING INCONTINENCE CARE

ABENA Group, an international manufacturer of healthcare products, has developed a digital incontinence product called ABENA Nova. The product is designed to provide a better quality of life for both incontinence product users and healthcare professionals. The ABENA incontinence diaper is no ordinary diaper. It features sensors and a small clip that transfers data via Bluetooth and 4G networks to the WetSens Monitor app, which is installed on the caregivers’ mobile devices. Caregivers can easily and quickly monitor the diaper’s moisture status and be notified if it needs changing. The product saves resources and minimizes user discomfort. In addition, caregivers can also use the data collected to monitor the users’ fluid levels. However, the innovative product could not be manufactured at the ABENA production facilities, which led the company to seek a skilled engineering consulting partner to assist in completing the necessary upgrades.
Industrial & Consumer Goods
Case

TRANSFORMING DATA CHAOS INTO STRATEGIC ADVANTAGE

2care4 is a European medicine distributor with experience in parallel import of pharmaceutical products within EU/EEA countries. 2care4 receives and processes large amounts of data every day to determine and monitor their product range. The company had been working on digitization and digital support of their workflow and decision-making processes. However, they had reached a point where they needed to restructure their systems and data. They defined a project to develop a new digital platform that would help them optimize their internal processes.

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