Thursday, July 24, 2025
Bosch Rexroth is committed to driving energy efficiency in its production facilities around the world. The company continues to make significant strides toward reducing energy consumption and cutting carbon emissions by adopting innovative solutions across its global plants. With creative thinking and careful analysis, the company demonstrates how modern technology and thoughtful process adjustments can lead to substantial energy savings.
At Bosch Rexroth’s Lohr plant in Germany, one of the company’s key operations involves the production of hydraulic castings. In this facility, castings are made in several different grades of cast iron, with a critical part of the process being a special heat treatment known as annealing. During annealing, castings are heated to over 900°C, then carefully cooled to precise specifications.
However, annealing requires enormous amounts of energy. Bosch Rexroth’s experts have found a way to make this process more energy efficient. The company has replaced the energy-intensive annealing process with slowdown cooling in a new, state-of-the-art cooling house. This adjustment has helped to significantly cut down energy consumption, reducing the carbon dioxide emissions of the Lohr foundry by over 2,500 tons annually. This development has a direct impact on the carbon footprint of Bosch Rexroth products, making them more sustainable.
In another move toward energy efficiency, Bosch Rexroth has installed a third medium-frequency melting furnace at the Lohr foundry. This new furnace is designed with cutting-edge technology that maximises energy efficiency, replacing three older ovens. Along with the new furnace, Bosch Rexroth has digitised and automated the melting processes, improving material flow and reducing the amount of iron transportation. By making these changes, the company has further reduced energy use, saving up to 2.9 GWh of electrical energy annually.
These improvements in the melting process showcase Bosch Rexroth’s commitment to sustainable manufacturing practices, reducing energy costs while increasing efficiency. The company’s focus on modernising production processes is helping it stay ahead in an increasingly eco-conscious market.
At Bosch Rexroth’s Beijing plant in China, energy-saving initiatives are also taking place. The plant produces hydraulic components, a process that involves compression refrigeration systems. These systems work similarly to refrigerators or air conditioners, emitting warm air that must be removed by a ventilation system, resulting in high energy consumption.
In response, Bosch Rexroth looked into using the existing cold-water network already in place at the Beijing plant. This network, which cools other machines and production processes, was integrated into the cooling systems for machine tools. By switching to this centralised heat exchanger system, the company significantly improved energy efficiency. The result was a reduction in energy consumption for cooling by over 80%, saving about 85,000 kWh per year.
This improvement highlights how optimising existing resources and infrastructure can drive significant energy savings. Bosch Rexroth’s move toward more centralised systems helps the company reduce its overall energy consumption without the need for additional equipment or drastic changes to the production line.
In Xi’an, China, Bosch Rexroth has introduced another energy-saving measure in the circuit board production facility. The plant used to cure synthetic resins by heating them to about 100°C for 15-20 minutes, followed by a two-hour cooling period. This process was not only time-consuming but also energy-intensive.
Bosch Rexroth’s team in Xi’an implemented a new solution using UV radiation to cure the resins. The use of UV rays causes the required chemical reaction almost instantly, eliminating the need for heat-based curing. This change saves over 80% of the energy previously used per printed circuit board (PCB) and reduces the drying time by about 90%.
Not only does this process consume far less energy, but it also allows for a thicker paint coating, offering better protection and higher quality for the circuit boards. By integrating UV technology, Bosch Rexroth’s Xi’an facility has made significant strides in improving energy efficiency while also enhancing product quality.
These examples are just a few of the more than 1,000 energy-saving initiatives that Bosch Rexroth has implemented across its global operations. Energy efficiency is a key aspect of the company’s commitment to operational sustainability.
Leo Pototzky, Director of Operational Sustainability at Bosch Rexroth, explained, “Energy efficiency is the key in cutting energy costs.” The company continues to explore new ways to reduce energy consumption while maintaining its high standards of product quality and operational excellence.
Bosch Rexroth’s energy-saving initiatives not only help the company reduce operational costs but also make a meaningful contribution to environmental sustainability. With these ongoing improvements, the company sets an example for other manufacturers looking to reduce their carbon footprint while boosting energy efficiency and productivity.
These global initiatives highlight Bosch Rexroth’s commitment to making a positive impact on the environment through innovative energy management solutions. As the company moves forward, it will continue to prioritise energy efficiency as a central aspect of its operational strategy, ensuring that its manufacturing processes are both sustainable and economically viable.
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