Refurbishment instead of replacement
Elektro Hagl, based in Geisenfeld, Germany, produces the CHP systems, which generate both electrical and thermal energy. These systems are designed to achieve high efficiency, utilising primarily natural gas or biogas as fuel sources. 

However, the charge air coolers which had been in operation for several years, were no longer delivering the required performance. The customer was looking for a cost-effective solution that could restore the coolers to their full operational capacity without the need for a complete replacement. The goal was to refurbish the existing systems, saving on both material costs and reducing waste by reusing as many original components as possible.

The solution
Kelvion was able to meet the challenge. Our team delivered a newly designed heat transfer surface, restoring the heat exchange performance to 100%, just like a brand-new cooler, but at a fraction of the cost. The refurbishment ensured that Elektro Hagl could continue to meet its operational requirements with minimal investment.

By reusing the existing parts where possible and replacing only the necessary components, the solution offered both an environmentally friendly and economically viable alternative to buying completely new units.

Achieving the goals
The refurbishing project achieved Elektro Hagl’s goals of reducing costs and minimising waste. 

“We are pleased with Kelvion’s solution, which enabled us to restore our charge air coolers to full capacity while keeping costs down,” said Martin Heidersberger, Elektro Hagl. “The ability to reuse the original components and still achieve optimal performance was a key factor in our decision. Kelvion’s support and technical expertise made this process smooth and efficient, and we look forward to continuing our successful partnership.”

The result
Elektro Hagl and Kelvion’s collaboration continues to grow, with multiple orders for charge air cooler refurbishments scheduled. As part of an ongoing commitment to performance and sustainability, Elektro Hagl remains a valued partner, trusting Kelvion to provide effective, cost-saving solutions in the field of thermal management.