CASE STUDY:  

Energy Savings with Intelligent Storage System

Driving Efficiency in Modern Intralogistics

Hawle Austria Group, a leading manufacturer of valves and fittings for water and wastewater systems, operates a global network of production and distribution facilities. As part of its continued growth and modernization strategy, Hawle invested in a new automated high-bay warehouse to improve logistics performance and support increasing operational demands.

To ensure long-term efficiency and sustainability, Hawle partnered with Hörmann Logistik and SEW-EURODRIVE to implement an advanced energy management solution. The goal was to reduce power consumption while maintaining high performance in storage and retrieval operations.

 Challenge:

High Power Demand in Automated Warehouse Systems

The new high-bay warehouse introduced significant energy demands due to the size and performance requirements of the storage/retrieval systems.

Each system:

    • Reached heights of 95 feet
    • Weighed approximately 25 tons
    • Required 60–70 kW peak power under conventional designs

Key challenges included:

    • High peak power demand from storage/retrieval systems
    • Increasing energy consumption with automated operations
    • Need for improved efficiency without compromising throughput
    • Limited optimization potential with traditional power supply concepts
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Automated Storage / Retrieval System
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Roller Conveyors on AS/RS System

Solution:

Advanced Power and Energy Management with Powercaps

SEW-EURODRIVE and Hörmann Logistik developed a comprehensive energy management solution centered around double-layer capacitors called Powercaps, enabling efficient energy storage and reuse within the system.

Key components of the solution included:

This solution captures energy generated during load movements, such as when hoists travel downward, and reuses it for subsequent operations. The result is a highly efficient, self-optimizing energy cycle within the warehouse system.

 "By using this innovative energy management solution, we're saving 230,000 kilowatt hours per year. That's the same amount of electricity used by 52 average households." 
— Andreas Bamberger, energy manager at E. Hawle Armaturenwerke GmbH

 

Results:

Significant Energy Savings and Reduced Power Peaks

The implementation of SEW-EURODRIVE’s energy management solution delivered substantial improvements in both efficiency and system performance.

Key results include:

    • 7–10x reduction in peak power demand
    • Approximately 230,000 kWh saved annually
    • Energy savings equivalent to ~52 households
    • Reduced total energy consumption and operating costs
    • Improved overall system energy balance

Additional measures, such as LED lighting, frequency inverters, and heat recovery, further contributed 10,000–100,000 kWh in annual savings.

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Why is Matters:

By integrating intelligent energy storage directly into the system, SEW-EURODRIVE enables customers to significantly reduce peak power demand and overall energy consumption. This approach not only lowers operating costs but also supports sustainability goals by improving energy efficiency at a system-wide level.

The result is a high-performance intralogistics solution that is both environmentally and economically optimized.

Application Summary:

SEW-EURODRIVE Product(s):

Application Area:

  • Automated Storage/Retrieval System
    (High-Bay Warehouse)
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CUSTOMER:

 Hawle Austria Group

INDUSTRY:

Manufacturing

APPLICATION:

Automated Storage / Retrieval System (High-Bay Warehouse)

SOLUTION:

 Power and Energy Solutions
 MOVI-C®  Modular Automation System 
 MOVIDRIVE® frequency inverters
 MOVIKIT® Stackercrane Software Module
 Gearmotors with MOVIMOT® Inverter 

 

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About SEW-EURODRIVE

Founded in 1931 in Bruchsal, Germany, SEW-EURODRIVE is a global leader in Industrial Automation, with operations in over 50 countries, 17 manufacturing plants, 92 assembly facilities, and more than 21,000 employees. The company holds over 1,000 patents, continuously driving technological advancements in gearmotors, frequency inverters, servo drives, and Industry 4.0 solutions.

SEW-EURODRIVE provides engineered solutions in countless industries, including automotive, food & beverage, pharmaceuticals, mining, steel, logistics, energy, and more, providing customized automation solutions that enhance efficiency, productivity, and sustainability. Despite its global reach, SEW-EURODRIVE remains family-owned, ensuring long-term vision, strong values, and a commitment to excellence.

SEW-EURODRIVE. Driving the World™

SEW-EURODRIVE, Inc.
220 Finch Road
Wellford, SC 29385
(P): (864) 439-7537
cslyman@seweurodrive.com
www.seweurodrive.com 

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