CONNECTEDMANAGING VIRTUAL DATA WORLDS SAFELY SUCCESS STORYDIESEL – AN IDEA THAT STILL MAKES SPARKS FLY TODAY

SPECIALIST STAFFCAIRN LAUNCHES TRAINING PROJECT IN INDIA

I S S U E 3 . 1 3

KN

OW

LED

GE

MA

GA

ZIN

E B

Y T

ÜV

RH

EIN

LAN

D

co

nta

ct

04

WORKING IN THE DATA CLOUD? YOU BET!

ALL DATA, anytime and everywhere: The advantages of mobile communication are undeniable and have an increasing impact on our daily lives. Mobile devices and services such as cloud com-puting, however, are also a nightmare for many IT departments. After all, it is getting more and more difficult to control who has access to which data and when. No doubt – a worldwide net-worked IT presents many challenges for companies in terms of security. But not participating is not the answer. The gains in efficiency thanks to modern IT technologies are too plentiful as to disregard them. The only correct advice for entering the cloud is therefore to minimize one’s risks. Deutsche Börse Cloud Exchange is making a step in this direction. The subsidiary of Deutsche Börse AG will start trading storage capacity and computing power of such cloud provid-ers in 2014, provided they have undergone a comprehensive certification procedure in terms of data security and data protection. This creates orientation. Read more on how IT affects our daily lives and why there is no way around the cloud (from page 4).

16

24 28

30

18

Content / Editorial02 contact 3.13

Dr.-Ing. Manfred Bayerlein, CEO of TÜV Rheinland AG

Companies around the world are also concerned about the topic of energy effi ciency. German companies in particular have been able to achieve re-markable results, if nothing else due to high energy costs. In light of these developments, Berzelius Stolberg, one of the largest lead smelters in the world, has voluntarily complied with all relevant energy management sys-tem standards since the 1990s. The result: Berzelius has been able to save up to 66 percent of energy consumption in individual process steps (page 28).Furthermore, we report on a worldwide unique pilot project to develop CO2-free parcel delivery using electric vehicles (page 20) and, just in time for the Christmas holidays, ask Playmobil CEO Andrea Schauer why Playmobil is still able to capture the hearts and minds of children after 40 years (page 30).Moreover, our new series “The world of labs” offers you unusual insights. We kick off the series with the environmental analysis lab in Cologne, where hailstones crash into motorhome roofs and components of offshore plants are sprinkled with salt spray (page 16).

Finally, I hope you enjoy our stories and are able to take away many new insights,

KNOWLEDGE

04 Hot Topic: Information security A networked world – curse and blessing

06 Hot Topic: Cloud Deutsche Börse Cloud Exchange ready-to-go

10 Hot Topic: Networked car How humans and cars connect securely

12 Hot Topic: Mobile working Not always healthy, sometimes downright dangerous 18 Not to be underestimated

A globally applicable method determines the CO2 footprint of products

24 A question of pressureDiesel is no longer just diesel. How additives refi ne a fuel

REGIONS

16 Indoor testing for out-door infl uencesThe environmental simu-lator knows all types of weather and checks how products react to it

20 Bonn delivers electrically Deutsche Post launches CO2-free parcel delivery with StreetScooters

22 No country for specialist staff

Emergent countries are looking for fully-trained staff, but no one wants to train them. The Cairn project offers help

28 No-go for bare feet A visit to the Berzelius lead smelter, which has gained impressive insights into energy management

PEOPLE

30 Playmobil makersWhy Playmobil is still able to capture the hearts and minds of children after 40 years and why it preserves the environment in doing so

SPOTLIGHT

14 The modern pilgrim takes the Metro to Mecca, the Fort Pitt Block House undergoes an x-ray examination, and other news. Plus: important TÜV Rheinland dates at a glance

03contact 3.13

WHETHER IN BUSINESS, INDUSTRY, communica-tion or entertainment: information technology can be found everywhere. People can be contacted at any time and information and news retrieved anywhere: never before has the world been so well connected. Information technology has an impact on the way we work together and on the way we communicate and

consume. It shortens distances; everything and every-one is mobile and connected. Devices, applications, data, smartphones and tablets present us with new freedoms. Information technologies such as the cloud are driving this development even further: they are the basis for new business concepts and are well on the way to becoming a key determinant for the future viability

A CLOUD IN THE SKIES OF THE STOCK EXCHANGE

contact 3.1304 contact 3.1304 Hot Topic Information Security

Information technology

plays a major role at the

stock exchange. In 2014,

the cloud will reach the

largest trading market.

of companies. The cloud can trigger economic growth, make processes more effi cient and increase the compet-itiveness of companies. And this will be even easier in the future. The fi rst quarter of 2014 will mark the start of the Deutsche Börse Cloud Exchange, making trade in storage capacities and computing power as simple as trading raw materials. But that is only one face of in-

formation technology, because the connected world involves as many risks as it does opportunities. Con-sequently, the demand for complex security solutions will increase. Read on to learn why companies should venture into a connected future despite the risks, and how they can fi nd the right experts.

> INTELLIGENT STRATEGIES WITH THE CLOUD: What companies need to consider on their way into the data cloud and an inno-vation offered by the German stock exchange in cooperation with TÜV Rheinland in 2014.

> INTELLIGENT USE OF MOBILE DEVICES: How companies can provide IT security when using smartphones and tablets and why management needs to rethink the way it deploys them.

> INTELLIGENT FORMS OF MOBILITY: Totally connected and always online – is the car on its way to becoming a mobile device too? What security risks will this bring with it?

contact 3.13 05contact 3.13 05Information Security Hot Topic

THE DATA CLOUD IS DEAD, LONG LIVE THE DATA CLOUD! MISTRUST RUNS DEEP, BUT THE ADVANTAGES ARE EVEN STRONGER. HOW SMALL AND MEDIUM-SIZED COMPANIES CAN BEST PREPARE FOR THE JOURNEY INTO THE CLOUD.

MANAGING VIRTUAL WORLDS RE-LIABLY

contact 3.1306 conconconconcoconnnnnnnntatatactactacccctacccctaccccccccct ccccccttt 3t 333333t 3t 3333t 33t 3t 3t 3333 3tt t 3tt .13.13.1313.130000006060660666600660006606600000000006060666666060066000006006 Hot Topic Information Security

"WILL PRISM BE THE END OF THE CLOUD?" – "The NSA is harmful to cloud computing" – many news outlets were quick to write off one of the most signifi cant IT technologies of the decade in light of the NSA scandal. But sceptics could not be more wrong: cloud comput-ing is not heading towards an early grave; it is not even in intensive care. Market statistics and projections have shown that the technical evolution towards the cloud is irreversible. Cloud-based services are enjoying increas-ing demand, despite the high level of mistrust. Analysts expect an explosion of cloud-based projects by the year 2016, both in small and medium-sized companies and

in large corporations in Europe and North America. The benefi ts simply outweigh the reservations: potential savings, greater cost effi ciency and fl exibility, and new forms of collab-

oration in companies.

"Certifi ed Cloud Service" certifi ca-tion provides orientation

The way into the cloud is not al-ways easy for companies. "IT

departments have to learn to let go while still remain-

ing in control," explains Hendrik A. Reese, cloud computing expert at TÜV Rheinland. "In the past, companies used to focus on implementing IT measures themselves and controlling their

infrastructures. Today, the focus has shifted to

managing virtual worlds," he adds. According to Reese,

IT decision-makers are faced with structural questions like,

"When is the right time to switch to cloud services?" Sitting out the

problem is not an option." It is not unusual for specialist departments to sign

up for certain cloud services on their own accord if the internal IT department fails to respond to the demands. This creates a sort of shadow IT system, which bears the risks of security vulnerabilities and breaches in the en-tire IT portfolio," says the expert. At some point, no one is going to be able to track who can access what data and from where. "As a general rule, before a company decides on a cloud, it fi rst needs to defi ne its goals," says Monika Gül, Key Account Manager at TÜV Rheinland. Companies should check whether their existing infra-structure is suited to the integration of cloud solutions. Potential savings need to be calculated carefully ahead

of time. Those looking for the most se-cure IT solution and high quality service and performance can get an initial idea from certifi cates – but not all test marks are worth the same. The "Certifi ed Cloud Service" certifi cate from TÜV Rheinland stands up to the most comprehensive in-

ternational requirements. The security of cloud service providers is tested in terms of conceptional, functional and technical aspects, making it possible to detect po-tential risks in the architecture.

Testing performance pledges in detailAnother crucial element concerns the drafting of contracts between cloud providers and companies. Most attention should be paid to service level agree-ments (SLA), which outline the cloud provider's quantitative and qualitative services – in addition to the consequences – should the cloud service not be provided as expected. "SLAs give information on the provider's capacities and potential confl icts," says Reese. Before a company signs a contract, it must fi rst understand the legal situation in the country where the data is stored. "There is no state under the rule of law – not even Germany – where the government can be prevented from accessing the data in the cloud." Companies without the necessary expertise in cloud services should obtain external support in good time. This provides a solid basis for successfully introducing and managing cloud solutions and putting their eco-nomic advantages to good use.

PROJECTED TURNOVER WITH CLOUD COMPUTING IN EUROPE

So

urc

e: P

ierr

e A

ud

oin

Co

nsu

ltan

ts

3,525 4,421 5,696 7,381 9,54212,258

15,60319,533

23,93728,831

34,210

40,12846,502

0

10,000

20,000

30,000

40,000

50,000

2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Turn

over

in m

illio

n e

uro

s

«

Not all test marks are worth the

same.

contact 3.13 Information Security Hot Topic 07

CLOUD?""WILL PRISM BE THE END OF THE C – "The NSA – many news outlets is harmful to cloud computing" –e most signifi cant IT were quick to write off one of the

up for certain cloud services on their own accord if theinternal IT department fails to respond to the demands.This creates a sort of shadow IT system, which bears the

contact 3.13 Information Security Hot Topic 07

AS OF 2014, IT WILL BE CONSIDERABLY EASIER TO OBTAIN SERVICES FROM THE DATA CLOUD THANKS TO THE "DBCE MARKETPLACE" AT THE GERMAN STOCK EXCHANGE.

NEW OPPORTUNITIES –WHERE BULLS MEET BEARS

GAINING AN OVERVIEW of the cloud service market to buy what you really need is still a time and cost-intensive undertaking. This is all going to change as of Q1 2014 when the Deutsche Börse Cloud Exchange (DBCE) starts trading in IaaS (Infrastructure as a Service) re-sources. Specifi cally, the fi rst step involves offering storage and com-puting services, i.e. storage capacity and computing power.

Buyers can choose from various contract periods, volumes, places of delivery and jurisdictions where data is stored. The platform is also appealing to public administration offi ces and research facilities that require IT resources for a certain pe-riod of time or want to sell excess capacity.

Among the partners of this in-ternationally independent and neutral "Cloud Marketplace" are renowned companies such as Equi-nix, Host Europe, T-Systems and other domestic and international companies. Experts expect ad-ditional positive impetus for the cloud computing market because the trading platform allays any

fears previously held: all providers undergo a certifi cation procedure designed by TÜV Rheinland in co-operation with Deutsche Börse. Buyers can expect high levels of quality and reliability from the cloud service provider.

New standardsIn addition, DBCE will also stan-dardize contractual conditions, processes and billing procedures in such a way that allows the customer to compare large numbers of pro-viders, creating a new level of trans-parency with prices updated daily.

Against this background, analysts expect long-term cost reductions and interesting new price models. The units of the service can be scaled as desired, so that even small providers and buyers are able to en-ter the cloud marketplace – more quickly, more fl exibly and in better quality than ever before. «

Russia

79%

Spain

77%

France

63%

Germany

54%

The Netherlands

40%

PROPORTION OF SME's USING CLOUD COMPUTING

Source: Dynamic Markets

INFORMATION:Hendrik A. Reesehendrik.reese@de.tuv.com+49 174 1880252www.tuv.com/en/cloud-security

contact 3.1308 contact 3.130808 Hot Topic Information Security

SaaS = Software as a Service – The most common form of cloud computing: software in the form of programs or services is not sold to the user as a license; instead the user approves the software via the browser as necessary; the service can be expanded at any time. The model is also referred to as software on demand. Typical examples: Google Docs and Google Mail, Microsoft Offi ce, the Adobe Creative Cloud, Salesforce and virus scanners.

IaaS = Infrastructure as a Service – This includes the provision of resources such as computers, networks or storage. An IaaS lets users freely choose their own virtual computer clusters. Users are therefore respon-sible for the selection, installation, operation and func-tioning of their software. Examples: Amazon Elastic Compute Cloud (EC2) and the Sun Cloud.

PaaS = Platform as a Service – Allows companies to rent a computer infrastructure as required; the server is no longer located on the company's premises, but at the cloud service provider's. This form of cloud computing is used mainly by companies who develop their own software applications. The advantage: highly fl exible and dynamically adjustable computing and data capacity. Example: the web operating system Google Chrome.

Public cloud = A public cloud is operated by a pro-vider which openly offers its services to everyone over the Internet. The customer receives access via a back-end application. Examples: Google Docs and webmail services.

Private cloud = A private cloud is fully operated by a company. It is accessed via the company's own intranet and controlled by login and authentication. The private cloud is tailored to the requirements of the company. Reasons for operating a private data cloud: a higher degree of control over data security and data storage.

Hybrid cloud = A mixture of a private cloud and a public cloud. Certain services are called up from pub-lic providers via the Internet; sensitive applications or data are operated and processed within the company. The challenge lies in consistently classifying and separating the data to be processed and the business processes into critical and non-critical.

CLOUD WIKI: WHAT IS...?

54%Deutsche Börse Cloud

Exchange offers a high

level of quality and reli-

ability in cloud services.

contact 3.13 Information Security Hot Topic 09contact 333.13.13.1333 InInfoformrmrmr atatioionn SeSeSeSSecucucucuririritytyty HoHot tToToToT pipippiccc 09

A CAR THAT seeks out a parking spot by itself or communicates with other cars – in the future, cars will be fully connected and automated. Intelligent 360-degree sensors ensure that the car moves forward at walking speed when in a traffi c jam, re-moves the risk of an accident before it occurs, detects other vehicles and pedestrians in good time and understands traffi c signs. Cars pick out the gaps in the traffi c right away.

Chips incorporated into the pavement record the fl ow of traf-fi c and send the data to the vehi-cles. Autonomous mobility and fully connected traffi c reduce both accidents and fuel con-sumption. Autopiloted cars turn drivers into passengers, giving them time to do other things while on the road like watching TV, reading or checking emails. Voice controlled Internet and so-cial media as well as the control of comfort functions, such as regulating the air conditioning in the car via mobile devices, have already found their way into the cockpit. A fascinating future that requires increased use

MOBILITY HAS A NEW DIMENSIONTHE FUTURE OF THE CAR IS CONNECTED. WHETHER IT IS ALSO SUCCESSFUL IS A MATTER OF INFORMATION SECURITY.

The future is happening on the streets

• Nokia's Here brings maps and information on traffi c and surroundings into the car and combines the services in the car with those available on smart-phones and on the web.

of IT solutions in the vehicle – thus also increasing the possibil-ity of vulnerability and weak-nesses in the system. Will the automotive industry be calling for IT standards in the future? Will malware smuggled in via the car's communication inter-faces be able to take over digital engine control or the emergency braking or steering assistant? Will the car of the future be nothing more than a "mobile device" with a fi rewall and apps – with all the IT security require-ments with regard to technology and processes, with a view on the integrity and confi dentiality of user data and yet still relevant to road traffi c? To offer innova-tive solutions and concepts for the networked mobility of the future, the information security specialists at TÜV Rheinland have brought in the expertise of the Secaron AG. The Munich-based company has expertise in the fi elds of risk analysis and protective measures in car IT se-curity, making them Germany's leading independent service pro-vider for holistic information security under the umbrella of TÜV Rheinland. «

INFORMATIONSabine Riethsabine.rieth@de.tuv.com+49 221 56783 210www.tuv.com/informationsecurity

Insight into the

contact 3.1310

The future is h i

contact 3.131010 Hot Topic Information Security

Almost all innovations in the automotive sector are IT-driven. This also, and indeed primarily, includes car-to-x communication, an essential condition for connected mobility. Twelve manufacturers and suppliers hope that cars produced by various manufacturers will be able to communicate with each other (car to car = C2C) and

exchange data with an intelligent infrastructure (car to infrastructure = C2I) by 2015. The car as an intelligent control center for road conditions, weather, danger points, infotainment: all the data collected can be evaluated and provided to others. An exciting area for profi lers, data privacy experts and data thieves.

• BMW uses ConnectedDrive to offer navigation with current traffi c information in real time, Internet services and a butler for the driver.

• Google plans to have robo taxis on the road by 2017.

• Toyota's Autopilot is equipped in similar fashion, but with im-proved sensors.

• The Nissan Leaf has a 360-degree laser scanner that moni-tors the surroundings while the car is moving. It even assumes control of the car independently.

automotive world of tomorrow

11contact 3.13 Information Security Hot Topic

Almost all innovations in the automotive sector are IT-driven. This also, and indeed primarily, includes car-to-x

i i i l di i f d

exchange data with an intelligent infrastructure (car to infrastructure = C2I) by 2015. The car as an intelligent

l f d di i h d

11contact 3.13 Information Security Hot Topic

How do smartphones and tablets affect a person's health?Nick Herbst: In my experience, they have a positive impact at fi rst. The more enabled employees feel, the more satisfi ed most are with their job.

When does it get critical?Nick Herbst: When people don't manage themselves and their time well or if the target agreements of supervisors are completely over the top. However,

The use of mobile devices at work is not only a matter of information security. It often requires management to adopt a new way of thinking. An interview with TÜV Rheinland health expert Nick Herbst.

management has not yet become fully aware of this. People who are available all the time are still held in high regard. The ban on company e-mail and cell-phones after work introduced by various German companies is a step in the right direction, but hardly enough. It is only when multiple employees suffer a burnout that everyone starts wondering where the psychological stress they are under comes from. Mo-bile devices fuel the fl ames but the cause lies in the corporate culture.

"DON'T SQUEEZE THEM DRY"

PROGRESS IS ALL AROUND

contact 3.1312 conconconcontactactactact 3t 3t 3t 3.13.13.1313121212121212 Hot Topic Information Security

INFORMATIONNick Herbstnick.herbst@de.tuv.com+49 162 2029576www.tuv.com/ohm

What is the best way to shape mobile working?Nick Herbst: For example, by having binding rules on working times and availability and sticking to them. Managers need to understand that they cannot squeeze their employees dry. The company should clarify exactly what individual employees have to do and how long it should take. Managers, too, should ask themselves whether they are setting a good example in terms of work-life balance. Companies that do not develop an understanding of the idea that "performance plus health equals productivity" will run into staffi ng problems sooner or later, be it due to high absence rates or a lack of applicants.

"ONE STAFF MEMBER USES A SMART-PHONE, another uses a tablet – many com-panies offer their employees unrestricted access to sensitive company data, even from private mobile devices, without being aware of the security risk for the company," reports Frank Melber, mobile security expert at TÜV Rheinland. A mobile device management (MDM) solution is therefore a must for every organization looking to offer fl exible work-ing without jeopardizing the availability and privacy of its own data and intellectual property. An MDM system lets companies manage all mobile devices centrally from their premises. The software acts as a virtual barrier that only grants access to authorized devices. The IT administrator responsible can delete company data from the mobile device remotely if the device is stolen or lost. An ideal addition: portal solutions based on MDM solutions that enable secure, role-spe-cifi c remote access. Mobile fi le sharing solu-tions support secure data synchronization with the company network. Depending on

the provider, secured workspaces can be set up for collaborative work with external third parties, so that they do not necessarily need to access the company network. Companies not able to cover mobile security internally should consult an external service provider such as TÜV Rheinland. Specialists provide support from the planning to the imple-mentation of mobile device strategies. The internal IT department can automatically learn something new and the board can rest assured that everything possible has been done in terms of compliance.

MOBILE DEVICES SUCH AS SMARTPHONES AND TABLETS HAVE ALREADY BECOME PART OF EVERYDAY LIFE FOR WORKERS IN MANY INDUSTRIES. HOWEVER, IT SECURITY STRATEGY IS OFTEN NOT WATERTIGHT.

«

INFORMATIONFrank Melberfrank.melber@de.tuv.com+49 174 1880264www.tuv.com/informationsecurity

13contact 3.13 Information Security Hot Topic

MOBILE DEVICES SUCH AS SMARTPHONES AND

13contact 3.13 Information Security Hot Topic

14

MODERN PILGRIMAGE

A question for you: Which city has the most-used metro in the world? Shanghai? Tokyo? São Paulo? Wrong – it’s Mecca, at least during Hajj. The city of 1.8 million in Saudi Arabia is visited by up to three million pilgrims dur-ing this period. For seven days they visit the holy sites around Mecca; chaos on the streets is to be expected. That being said, the pilgrimage has become easier since 2010: The fully-automatic Al Mashaaer Al Mugaddas-sah Metro Line has replaced 50,000 buses and connects important sacred sites. In doing so, it transports up to 100,000 passengers per hour. Experts at TÜV Rheinland supported the construction of the Metro and ensured that it was approved by the Saudi Railways Commission (SRC). In addition to that, they are available each year and provide on-site advice on topics related to metro safety, before and during Hajj. This is the only way SRC can is-sue a safety certifi cate for the rapid transit railway, which stretches over 18 kilometers and nine train stations.

Spotlight contact 3.13

01. – 04./14

The Fira de Barcelona unites unique

architecture and modern technology.

01/13/2014 – 01/19/2014 Imm CologneThe International Furnishing ShowCologne/GermanyKoelnmesse GmbH ∙ Messeplatz 1 ∙ 50679 Colognewww.imm-cologne.com

01/29/2014 – 02/03/2014 Spielwarenmesse NurembergThe International Toy FairNuremberg/GermanyNürnbergConvention Center ∙ Messezentrum 190471 Nurembergwww.toyfair.de

02/11/2014 – 02/13/2014 E-world energy & waterPremier Fair in the Energy and Water IndustriesEssen/GermanyMesse Essen GmbH ∙ Norbertstraße 2 ∙ 45131 Essenwww.e-world-essen.com

03/10/2014 – 03/13/2014 EWEAEuropean Wind Energy Association Barcelona/SpainFira de Barcelona Gran Via ∙ Avinguda Reina Maria

Cristina s/n ∙ 08038 Barcelonawww.ewea.org

04/07/2014 – 04/11/2014 Hannover MesseThe World’s Leading Trade Fair for Industrial TechnologyHanover/GermanyDeutsche Messe ∙ Messegelände30521 Hanoverwww.hannovermesse.de

15

SAFETY ON CONSRUCTION SITESPlaying it safe remains the strat-egy for Audi when it comes to conquering the American market. The new construction of the fi rst factory on the continent close to Puebla (Mexico) is accompanied by TÜV Rheinland’s safety-related construction site coordinators (SiGeKo). Our transnational team recently helped to prevent acci-dents even during the expansion of the Audi plant in Hungary.

Old and unremarkable, yet still a treasure – the Fort Pitt Block House is the pride of Pittsburgh. It is one of the oldest remaining monuments in US history and will be celebrating its 250th anniversary in 2014. To mark the occasion, plans are under way to restore the structure, while applying the utmost care and sensitivity such a treasure deserves. The oak beams on the arrowslits in particular are proving quite a headache for the restoration company, as it had to

have an idea of the condition of the wood. Drill a hole and take a look – that is the way it is usually done. Instead, the experts at TÜV Rheinland took a full x-ray of the monument’s wooden beams. An unusual task, given that the technique is normally reserved for bridges or power plants. “An opportuni-ty like this only comes once in a lifetime,” says x-ray expert Chris Dugan, who was the talk of Pittsburgh for several days.

ARROWSLITS X-RAYED

APPLICANTSWITH STANDARDSApplicants are increasingly considering their potential em-ployer’s track record on social commitment and sustainable economic management. The www.csr-jobs.eu platform makes companies’ commitment trans-parent and gives them the op-portunity to present themselves on the website. TÜV Rheinland received the CSR Job Award for its CSR strategy and measures.

INTERNATIONAL WAVE

Non-destructive inspections are an elegant way to inspect welded seams on pipes with ultrasonic waves, for example. Acquiring the Hungarian company Minell with around 60 specialists has allowed TÜV Rheinland to further expand its international network in the fi eld of safety inspections for industrial plants.

Spotlightcontact 3.13

NATURE PERFECTLY RECREATED

INFORMATIONJörg Althaussolarenergy@de.tuv.com+49 221 806 5222www.tuv.com/solarenergy

THE ENVIRONMEN-TAL SIMULATION LABORATORY: INDOOR TESTING FOR OUTDOOR INFLUENCES

ONLY FOUR YEARS OLD BUT FAR FROM IMMATURE

The world’s largest and most state-of-the-art test center for solar modules opened on 22 June 2009 at the TÜV Rheinland campus in Cologne Poll. TÜV Rheinland invested about four million euros in the new construction and technical facilities. Since then, PhD physicists and graduate engineers, technicians, foremen, skilled workers and logistics experts have all been working hand in hand on an area encom-passing 2000 m². The test facilities are con-stantly being expanded and modifi ed to allow them to remain fl exible at all times and react to the ever-changing demands of the market.

LIGHT, WEATHER, AIR: WHAT THE LABORATORY CAN SIMULATE

> Hailstorms The impact on a product is tested at 155 km/h using special hailstones.

> UV test Four days in the chamber corre-spond to three months of global radiation in Central Europe. Additional weathering, for example using humidity, is possible.

Off to the climate chamber: materials and products

from windmills to conservatories are tested here.

TESTING FIELDS

«

HISTORY & LOCATIONH

«««««««««

“BANG!”: A DIRECT HIT. A hail-stone made from real ice and with a diameter of 35 millimeters crashes into a solar module at 155 km/h. The laboratory worker takes off his protective goggles and examines the point of impact. Not a scratch. Perfect. The velocity of a falling hailstone is actually only about 35 km/h. Test passed. Along with hail-storms, TÜV Rheinland’s environ-mental simulator is also able to rec-reate other weather conditions in order to test products under realis-tic conditions: extreme heat, freez-ing temperatures, high humidity, pressure and suction due to snow load, wind, air containing salt or ammonia, and prolonged exposure to sunlight.

Regions Labs all over the world16 contact 3.13

> Mechanical stress test The controlled ap-plication of force demonstrates the product’s resistance against pressure and suction, which occur during snow and wind.

> Climate simulation Shows the aging process of products under stress infl uences such as heat, cold and humidity.

> Continuous light Constant exposure to light simulates the behavior of light at noon on a summer’s day.

> Peeling test Determines the adhesive strength of materials and adhesive joints.

> Salt spray chamber Quality control of coat-ings by spraying salt mist at different severity levels.

> Ammonia test Testing of atmospheric corro-sion caused by ammonia or other corrosive gases as they occur on livestock farms.

> Driving rain test The test measures the water load by simulating falling rain accelerated by wind.

FLEXIBILITY: TESTING SERVICES NOT LIMITED TO THE SOLAR INDUSTRY

Test of climatic, mechanical and corrosive environmental infl uences is not limited to products from the photovoltaics and solar thermal energy sectors. Whether it’s manu-facturers of lacquer, tape or adhesives, the plastics and construction material industries are able to benefi t from these testing services just as much as the automotive sector or ag-riculture. Motorhome roofs, for example, are subjected to simulated hailstorms. Con-servatory components bake and freeze in the climatic chamber. Engineers test offshore plant parts for corro-sion resistance in the salt spray chamber. The range of testing possible in the envi-ronmental simulation lab is huge – and new areas can be added ac-cording to individual customer requests.

PARTICULARITYP

How resistant is

a roof system?

The driving rain

test will tell you.

New series: The TÜV Rheinland

laboratories open their doors.

Cologne is the starting point.

Part 1 >> Germany 17contact 3.13

Auf neuen Wegen: Mit

innovativen Produk-

tionsstraßen und

optimierten Verfahren

verbessert Prowell die

CO2-Bilanz der Produkte.

HOW MUCH CO2 IS PRODUCED DURING THE MANUFACTURE AND SHIPMENT OF A PARTICULAR PRODUCT? THE VALID BASIS FOR CALCULATING THE ANSWER TO THIS QUESTION IS OFTEN LACK-ING. THE PACKAGING MANUFACTURER PROWELL, IN COOPERA-TION WITH TÜV RHEINLAND, SHOWS HOW THIS DILEMMA CAN BE TURNED INTO A GENUINE MARKETING INSTRUMENT.

NOT TO BE UNDERESTIMATED

AufAufAufAuAufAufAufAuf neneneneneeuenuenuenuenuenuenuen WeWWeWeWeWeWWeWeeWeWeeW gengengengengegengengenegeneegeeegengenengeng ng nngggenggeneeegeggenggengeneengengggeeeeeeeeggg : M: M: M: MM: M:: M:: M: M: Mitititititittit

inniinnnnninnininninnnnnnnnninnovaovaovovovaovavovaovaovaovaovaovavaao itivivivttivtivtivtivtivtitivitivivitiiiiviiiviiviviviivvvivvvvivvvvvvvvvvvvvtivvvvvvvvvvvvvvvvvvvvvtivvvvvt vvenenenenenennene ProProPProProrororororoor d kdukddukdukd kddukkdukkdukdudukk---

tititiotioioioootiotttiotttioottttiotttttiotiotitttttiottttt otititittiottitttttittitttioottittttitittttttttttttiiotttitiioiiittioiiiott nsnsnnssssssssn ssssnn ssnsssssssstratratratratratrraaaratttr ßßßßßßenßenßenßenßenßeneßeß unununuununndddddd

opoptpoptoptoptttptptptptopptptptoptptpptpptptptptptptpptptpttttt mimimmiimmimimimmimimmmiiimimimimimiimimimimimimimmmmimimimiimimimiimiimimmmimiimmmiimmmmmmmmmimmmimmmmmmmmmimmmmmmmmmmmmmiimmmimmmimmmimmmmmiimiimmmiiimiierterterterterrtrtererteertteertteer enen en nnneneeneneen VerVerVerVeVerVerVerVerVereVerfafafafaaaaahahhhhffafaahaahaaahaaahaaaaaaahaaaaaaaafaaaaaaaaaa renrerenrrenenenenennreenrererr nrereer

verververervvvvvvvvvvv besbesbesessssssssbesssbeb sesssseserseererereererrrrrrrrrrrsesesserereerrrrrrrrsesesserrrrrrrsserrrrrrssesserrrrrses rrrrrrserrsesesss rerrert Pt Pt Pt Pt Pt PPPt Pt Pt Pt Ptt Pttttt t t ttttttt t tttttttt tttttttt tttttttttttttttttttt rorowrowowowowwwwwrororoowro eeeeeeellelleeeeeeeeeeeeeeeeeeeeeeeeeee didd ee

COCCCOCOCOOOOOOOOOOCOCOCOCOOOOOCOCOCOCOOOOOCOCOOOOOCCOOCOOOOOOOOOOOOOOOOOOOOCOOOOCOOOOOCCCCCCCCC 22222222222222222222222222222222222-BB-B-BBBiBBiiBBBiBBBBiBBBBBBiBi-BBBBBiii-BBBBBBBBBBBiiiBiBBBBBB-BBBii-Bi-B-BBBBBBiii-B-BBBBBiiBi-BBBBBBiiBBBBBBiBBBBBii-BBBBBBBB-Bi-BBBBBBBBBBiBBBBBBBBBBiBBBBBBBB-B-BBBBBB--BBBBBBBiiBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB llanlanlanlanlanlanlanllllllllaannlannnnnnnnnnnannnanannnnaananannananannnnnnnnnaanannnnnlaaaannaaaaaanaaaaaanaanaanaanaannnnannnnnnnnannnnnnnnaannnnnnnnnnaannnnnnannnnnnz dz dddzzzz dz dz ddz dz ddz dzz dz ddzz dz dz ddz zzzz dzz ddz ddddddzzzzz dz ddddz dddddz dddzz dddz dz ddddddzz ddz ddddz dz dddddzzz ddz dz dz ddzzzz dz dddzzzz dz dz dz ddzzzzzz dz dz dzzzzzz dz dz dzzzzzz ddzzzzzzzzzzz dzzzzz ddzzz ddddddddddz z ddddddddz deerer er erereereerrerrrrrrrreeererrrrrrrreererrrrrerrrrerrrrrerrerreeeeeeeeeeee PPPPPPrrrrorororoPPPPrPPPPPPPPPPPPPProPPPPPPPPPPPPPPPPPPPrPPPPPP dukddudddud te.te

Treading new paths: Prowell is

improving the CO2 values of products

thanks to innovative production

lines and optimized processes.

Knowledge CO2 Footprint18 contact 3.13

THE DEVIL IS IN THE DETAIL. In order make a concrete assessment of the CO2 footprint of a television, for ex-ample, many factors have to be taken into account: the production of components, the assembly and fi nally packaging and transportation. Accordingly, Prowell, one of Europe’s leading manufacturers of corrugated sheetboards, had been receiving a growing number of questions about emissions during packaging produc-tion. After all, the television manufacturer can only provide reliable information on carbon dioxide emis-sions if it has all the values for the packaging. The prob-lem is that international standards that could be used to compare Prowell’s products to those of the competi-tion had not yet been created.

Product rule developed for calculationTÜV Rheinland developed a solution and, at the same time, produced a world fi rst. For the fi rst time, Prowell applied the international ISO 14067 standard to mea-sure the CO2 footprint of products, even though the brand new standard is still in its draft stage. At the same time, a new standard was defi ned along with the certi-fi cation for eight different corrugated sheetboards. This standard is going to set the bar for all Prowell’s competi-tors in the future. Why? Because TÜV Rheinland has initiated a globally-applicable calculation method and a corresponding calculation standard based on it. The result is a “Product Category Rule” that applies to all CO2 calculations of corrugated sheetboards and which will be binding from now through June 2016. “Prowell has demonstrated its pioneering spirit in this coop-eration with us, which has led to transparency on the market,” says Alexandra Hohl, who acted as the project manager for TÜV Rheinland. She expects more compa-nies in other product and industry sectors to follow this example. “Due to the lack of credible information on

the CO2 emissions of various products and components statements, many companies are increasingly facing diffi cult questions. This problem can be solved by ap-plying reliable methods and calculation bases, as these form the basis for comparing values objectively.”

Calculation as a marketing instrumentExternal certifi cation is no longer required if the new ISO standard on carbon dioxide is fulfi lled, provided the results are published in accordance with the ISO standard. For Prowell, this precise calculation of CO2 emissions not only makes communication with the customer easier; it is also now being used as a tangible marketing instrument. After all, the newly developed corrugated sheetboards offer better stability than ever before, and at a lighter weight. Reviewing the new pro-duction plants was another important aspect for in-ternal evaluation, given that their effi ciency directly affects the calculation of the products’ greenhouse emissions. “Essentially, we want to be able to verify the sustainability of the products and production plants objectively. This is now possible and it is an important factor in favor of market and technology leaders. We not only offer data review for this purpose, but also de-velop the required, generally applicable methodology,” explains Alexandra Hohl.

Under scrutiny: Not only sheetboards have to demonstrate

their effi ciency – so do production plants.

On the move: The new generation of corrugated sheetboards

is lighter – this lowers emissions and transportation costs.

INFORMATIONAlexandra Hohlalexandra.hohl@de.tuv.com +49 221 806 2978www.tuv.com

«

CO2 Footprint Knowledge 19contact 3.13

E-COMMERCE GENERATES HUGE PROFITS FOR PARCEL SERVICES. A PILOT PROJECT FOR CO2-FREE DELIVERIES THAT IS UNIQUE IN THE WORLD IS BEING INITIATED IN BONN.

A POSTMODERNPOSTAL

Pioneer in intelligent mobility: DHL is betting on e-mobiles for urban delivery services.

Regions e-mobility20 contact 3.13

PEOPLE JUMP FOR JOY and their eyes light up when the postman rings at the door and fi nally delivers the ob-ject of their desire – at least that is what happens in tele-vision ads. One thing is certainly true: Online trade – ore-commerce – delivers great results. 33 billion euros passed through the virtual check-outs last year in Germany alone – an increase of nearly fi ve billion euros or 15 percent compared to the previous year. Fashion items and accessories are at the top of the list for online shoppers, followed by consumer electronics and electric appliances as well as hobby and leisure items, including books. Americans still remain the world champions of online shopping. In 2012, they purchased goods worth USD 272 billion over the Internet. In three years, ex-perts predict, this fi gure will have exceeded 580 billion. Courier, express and parcel services are also earning a fortune thanks to this digital shopping frenzy. Last year saw an increase of 4 percent to almost 2.6 billion individual shipments in Germany. Around three mil-lion packages are delivered every day by the market leader Deutsche Post DHL alone. More and more deliv-ery trucks are making their way through cities threat-ened by traffi c gridlock – CO2 emissions are on the rise. While computer-aided logistics solutions (the key con-cept is logistics routing) help in optimizing the delivery order, scheduling and route planning, electric vehicles are reducing the amount of greenhouse gases.

Postal service moving towards electric vehiclesDeutsche Post has responded to this. The company is converting its fl eet to electric vehicles and hopes to make the city the fi rst location in the country with a CO2-free vehicle concept. The plan is for around 80 electric vehicles of various sizes and makes to be in use in the delivery service by the end of this year. By 2016, the near-silent fl eet is to be expanded to 141 vehicles,

which will result in a CO2 reduction of 500 tons. “Our pilot project is unique in the world and can set an ex-ample for other cities and regions,” said Deutsche Post CEO Frank Appel during the presentation held in May of this year in Bonn. When it comes to parcel and let-ter delivery in metropolitan areas in particular, electric engines can reduce noise and environmental pollution considerably. Together with Aachener StreetScooter GmbH and the institutes of RWTH Aachen University, Deutsche Post DHL has developed its own electric ve-hicle specially designed for the challenges of delivering letters and parcels. StreetScooter began delivering the fi rst preproduction batch in summer of this year. 50 cars should be in use by the end of 2013, 20 of which will be added to Bonn’s e-fl eet, while another 30 will be distributed nationwide.

DIN EN ISO 9001 for StreetScooterHowever, before StreetScooter GmbH can build and sell large numbers of these electric workhorses, they will have to undergo the company’s certifi cation process. “At the moment, the vehicles are being licensed indi-vidually,” says TÜV Rheinland expert Manfred Hoo-gen. “For example, we have tested the seatbelt anchor strength in our labs and will test the company’s quality management system by the end of the year using the DIN EN ISO 9001 standard. In addition, statutory safety and environmental standards need to be fulfi lled for se-ries production. In doing so, we are creating the condi-tions required by the authorities for the type approval of the StreetScooter.” Following a type inspection by a nominated technical service provider, the Federal Mo-tor Transport Authority uses these conditions as the basis for the type approval for vehicles produced in se-ries. The type approval then allows the vehicles to be approved for use in public traffi c. «

The 4.6 m-long StreetScooter has a range of approx. 80 kilometers. The electric motor has a peak performance of 45 kW. The maximum speed

is about 85 km/h. The car must be able to handle up to 200 stops and starts each day in order to deliver letters and parcels.

Founded in 2009, StreetScooter GmbH is an out-sourced project of RWTH Aachen University and a consortium of around 80 industrial companies from the automotive sector. Its goal is to research, develop and manufacture sustainable vehicle concepts. The fi rst prototype of the StreetScooter was introduced at the IAA in Frankfurt in 2011.

SILENT WORKHORSE AACHEN-BASED THINK

INFORMATIONManfred Hoogenmanfred.hoogen@de.tuv.com+49 221 806 1931www.tuv.com/e-mobility

e-mobility Regions 21contact 3.13

FLY, SPARK, FLY

Engineering engines: Unfortunately, many workshops around the world are in dire

need of trained mechatronics engineers – training centers are the solution.

Regions Cairn project in India22 contact 3.13

COMPANIES FROM INDIA TO BRAZIL ARE DESPERATE FOR SPECIALIST STAFF. BUT THEY DO NOT SEE IT AS THEIR JOB TO TRAIN THEM. CAIRN INDIA IS DOING SOMETHING ABOUT IT.

“WHEN YOUR HANDS ARE SWEATING and sparks are fl ying, you know you’re learning in real-life conditions,” says Indian Subhadra Vinod. He is learning welding by welding, from teachers who can weld themselves, somewhere where sparks are allowed to fl y: at the TÜV Rheinland Training Center for Welding Technology and Vehicle Mechanics in Pollachi,southern India. Subhadra Vinod has hit the nail on the head, as practical training is not a matter of course for young people in India. They usually go straight into a job after leaving school, without enjoying a proper ap-prenticeship fi rst, or they attend institutions such as colleges, where they gain theoretical knowledge that is often outdated and irrelevant to the needs of industrial companies. After all, these companies are changing. While they used to need cheap labor for mass produc-tion, today more and more companies from the vehicle sector, machinery construction and the construction industry are looking for trained specialist staff. Another trend is the increasing awareness of quality, as foreign investors produce according to international standards and conduct quality controls.

Everyone wants capable staffThe gap in qualifi cations in technical professions af-fects not only India, but also other major players such as China, Russia and Brazil, who are starting to get in-volved in the global market and are looking for prac-titioners who can maintain wind turbines, weld pipes and check quality. Brazil, for example, will need around another 7.2 million additional technicians and engi-neers by 2015, while India will be short of around 50 million specialist staff by 2020. Everyone wants capable staff, but no one is investing in training them. Cairn India, one of India’s largest oil and gas producers, is leading the way as a supporter of education. The com-pany‘s project team, led by Sr Manager for Strategy, Sidharth Balakrishna, is founding the “Cairn Centre of Excellence” (CCoE), a modern vocational education center in Jodphur, a city of over a million people in the north-western Indian state of Rajasthan. “The Cairn Centre of Excellence will offer local youth the oppor-tunity to benefi t from the country’s growth and that of Rajasthan,” says Elango P, Interim CEO Cairn India.

The practical training provided includes the installation and main-tenance of energy sys-tems, process technol-ogy in the automotive segment, welding tech-nologies and retail. The

range on offer also includes soft skills such as time man-agement and seminars on management systems. Over 1000 training places will be available in the fi rst two years from 2014.

Training centers close the gap in qualifi cationsCairn is drawing on the help of TÜV Rheinland, as an experienced partner with international expertise in training concepts, in the project’s organization. TÜV Rheinland is acting as the operator of the CCoE, provid-ing specialist staff and developing the curricula – all in line with German engineering and educational stand-ards. “The Cairn project is a cornerstone of the contin-ued internationalization of our Training and Consult-ing division,” says division head Siegfried Schmauder, pointing to the 12,000 classes held in 72 topic areas by over 2,500 teaching staff all over the world every year. In addition to the training center in Pollachi, southern India, there are others in Brazil and China. The train-ing center for vehicle mechanics will open in Shanghai in late 2013. Places are hotly contested, as many com-panies send their staff there to qualify them for work in vehicle workshops. As well as factory training focusing on welding and automotive, the centers in India, China and Brazil also offer shorter seminars on CO2 manage-ment, energy effi ciency, fl ows of materials and emissions management. Graduates of the center need not worry about fi nding work – just like Subhadra Vinod, who made contact with companies even during his training. «

INFORMATIONP Prabakaranprabakaran@ind.tuv.com+91 422 301 8290www.tuv.com/global-academy

Training at the “Cairn Centre of Excellence” starts from 2014.

Cairn project in India Regions 23contact 3.13

High-performance

cocktail: Additives turn

diesel into high-tech

products.

Knowledge Fuel24 contact 3.13

FROM LOSER TO SPORTS STAR: DIESEL’S AMAZING SUCCESS STORY.

HIGH-TECH DIESEL ENGINES NEED HIGH-PERFORMANCE FUELS.

A SPARK OF GENIUS

THE PRESSURE IS HUGE. Inside a modern diesel engine, the injection nozzles push the fuel into the com-bustion chambers through tiny ori-fi ces just 0.09 millimeters in diameter, at a pressure of up to 2500 bar. That is the same load as a column of water around 25,000 meters high, and feels as if a male rhinoceros were standing on your toe. “The high injection pres-sure causes the fuel to be nebulized extremely fi nely in the combustion chamber. This means that the very last quantum of energy can be ex-tracted, combustion optimized and fuel consumption and emissions re-duced,” says Thomas Kampmann, Head of Vehicle and Component Tests at TÜV Rheinland.

As well as direct injection, turbo charging and cylinder deactivation, the magic word for engine builders today is ‘downsizing’. This means a smaller engine displacement or fewer cylinders, while retaining the same or even increasing performance. The energy required, and therefore con-sumption, falls. The 1.5-liter CDI turbo engine in the current compact Mercedes Benz A class mobilizes 80 kW (109 horsepower). Mercedes Benz claims that it consumes just 3.6 liters of diesel per 100 kilometers. In doing so, the direct injection diesel engine emits just 92 grams of the greenhouse gas carbon dioxide (CO2) per kilome-ter. For comparison: A Mercedes mid-range sedan from the 1970s, such ›

Fuel Knowledge 25contact 3.13

2,500 kg“Imagine a rhinoceros weighing 2,500 kilograms standing on your toe. Then you would certainly be able to understand the pressure the common rail system puts the fuel under before dispersing it fi nely at the speed of a supersonic jet.”

DIESEL OR GASOLINE

FOAM-FREE

The key difference between gasoline and diesel engines is the type of combustion. In a gasoline engine, the ignitable mixture of fuel and air is compressed and ignited by a spark plug. In a diesel engine, air is compressed to such an extent that the injected fuel self-ignites when mixed with hot air.

Special additives increase theperformance of diesel fuel.

> Anti foam products go a long way in preventing the annoying formation of foam when fi lling up a vehicle; the fuel does not overfl ow and does not enter the environment.

> Flow improvers keep even the tiniest paraffi n crystals suspended for longer and improve fl owability, especially at low temperatures.

Detergents and dispersants prevent sedimenta-tion and keep the fuel system clean.

> Corrosion inhibitors protect metal partsin the fuel system and prevent faults andmaterial damage.

> Ignition accelerators improve the fuel’s ignit-ability. Increasing the cetane number optimiz-es combustion, thus protecting the engine, improves cold start behavior and reduces noise and harmful emissions.

Pressure vessel: The fuel

is stored and dispersed

to the injection nozzles

in the common rail.

PPrPPPrPrrerereePrPPreP ssussure re vesveesessveesssse sessessesee

isisisisisss s iss is storedddddre ananannnaa d dd ddddd dd dd diiiiiiisisiiis

ttttttoooot thethe ininiinni jejecececceccecccctiotiotiotiotiotiotiotionn n nn nn n nn nnnn n nnnnn oo

iiini the cocococooommommommommommommommommmmommommommomon rn rrrnnn rn rn rrn aaailaaailailila ll

Knowledge Fuel26 contact 3.13

as the 200 D, produced a meager 40 kW (55 horsepow-er) from two liters of engine displacement, and guzzled nine liters of diesel per 100 kilometers, with CO2 emis-sions of 240 grams per kilometer.

Diesel racing aheadThat said, diesel engines have enjoyed a wonderful suc-cess story, which began with the fi rst series diesel en-gine in the Mercedes 260 D (33 kW/45 horsepower) at the Berlin car show in February 1936. Diesel cars were considered economical and long-lasting, but also had an image as a bit of a bore. However, they are no lon-ger the losers and wallfl owers they once were. In 1975, the VW Golf Diesel was the fi rst compact car with a die-sel engine, and its fast, economical engine (37 kW/50 horsepower) triggered a real diesel boom. Back then, the Bosch injection system was still operating with a pressure of a modest 300 bar.

Today, diesels are considered effi cient and fun to drive. In Germany and across Western Europe, half of all new cars run on diesel. Mid-range and luxury sedans in particular are increasingly popular as company cars. Alongside other varieties of direct injection, common rail technology became popular in the late 1990s. In this technique, the fuel is stored at a constantly high pressure for all cylinders in a usually tubular common rail and then dispersed to the electromagnetically con-trolled injection nozzles. This allows extremely fi ne nebulization thanks to multiple injections just milli-seconds apart in each injection process, as well as en-suring quieter running and lower harmful emissions.

The demands on fuel quality are growingBut high technology comes at a price. “Delicate com-ponents with their tiny orifi ces are susceptible to sedi-ment and contamination,” explains Wolfgang Dörmer, fuel expert at Aral research, part of the BP Group, in Bochum. “That is why the development of special ad-ditives for fuel is becoming ever more important. These chemical additives, which are mixed into the basic fuel when tankers are loaded at the refi nery, ensure that the engine remains clean, among other advantages.” Just like lubricants, fuels have now become construction elements for engine builders. The experts at Aral work together closely with the automotive industry and component manufacturers in order to guarantee that the constantly increasing requirements of fuel quality are met.

Another advantage of premium fuels such as Aral and BP Ultimate Diesel is that, by breaking down existing sedimentation in the injection nozzles and prevent-ing new deposits from forming, they are able to reduce

wear and tear compared to conventional fuels. In addi-tion, they protect steel elements in the fuel system from corrosion and do a lot to prevent foam from forming when the vehicle is fi lled up. TÜV Rheinland has veri-fi ed this, too. “Following success in the Netherlands, Switzerland, Austria and Germany, we have now con-ducted fuel analyses for Ultimate Diesel on behalf of BP in Turkey and taken samples from gas stations in Istanbul, Ankara and Bursa,” reports graduate engineer Thomas Kampmann. After checking the basic fuel in Turkey, Aral research also conducted further investigations into the verifi cation and effect of the additive package. The result: clean motor, everything is good, quality seal awarded.

Post-laboratory: Experts from the Aral research department

and TÜV Rheinland analyze the results.

«

INFORMATIONThomas Kampmannthomas.kampmann@de.tuv.com+49 221 806 1969www.certipedia.com ID number 980 (BP NL), 39283 (BP TR), 2000000980(BP A), 1000000980 (BP CH)

Fuel Knowledge 27contact 3.13

A PLANT TOUR OF AN EARLY ADOPTER OF THE DIN EN ISO 50001 STANDARD WHOSE MOTIVATION IT IS TO BE AN EVER BETTER ROLE MODEL FOR ITSELF.

ANYONE PLANNING TO VISIT THE BERZE-LIUS BLEIHÜTTE smelter should pay care-ful attention to their choice of shoes. Why? Because even if temperatures outside exceed 30 degrees, sandals are an absolute no-go. If you are not wearing safety clothing then you are not going to see the inside of the Berzelius Bleihütte (BBH) in Stolberg, one of the largest and most modern lead smelt-ers in the world. 10.6 million tons of lead were produced worldwide in 2012, around 155,000 tons of which were produced in Stolberg, a small town near Aachen. As lead is found in so many industrial products, de-mand for the base metal is increasing. Start-er batteries for cars, accumulators, optical lenses, machines and buildings, roof cover-ings and cable protection jackets all contain lead. It can be recycled any number of times without losing quality or value. “The BBH is not among the most energy-intensive op-erations,” explains chemist Heiko Ambroz. The energy consumption during lead man-ufacturing accounts for just seven percent of the company’s gross value added, but the cost pressure from competitors in Russia and China is enormous. “When you are dealing with a complex process like lead production and an average annual energy consumption of 300 GWh, it makes sense to keep a close eye on energy costs,” he adds. In Stolberg, lead is extracted from lead ore and second-ary raw materials. The QSL process used here is considered one of the most modern, en-vironmentally friendly and effi cient in the world. Since the 1990s, BBH has voluntarily complied with all relevant energy manage-

Regions Berzelius energy management28 contact 3.13

ment system standards. Most recently it has become one of the earliest adopters of the DIN EN ISO 50001 standard, certifi ed by TÜV Rheinland. “Tax incentives were not the main concern in doing so,” emphasizes Dr. Urban Meurer, Managing Director, “but rather the competitive drive to constantly improve the process further.” Since then, the technology leader has professionalized its energy management considerably. Heiko Ambroz points to the energy meter near the process tank, whose data are processed in the process control system. “Until the year 2011, we took measurements manually from far fewer measuring stations, entered them into a ‘meter book’, recorded them in Excel in Controlling and compared them with the incoming invoices of the energy suppliers according to internal calculation keys.”

66 percent energy savingsToday, the measuring process is automated and much more sophisticated, and the net-work of measuring stations has been ex-panded from 30 to 40. “Instead of monthly values, the actual state in the system is now updated at 15-minute intervals. Corrective measures can now be taken in real time if there are any deviations or malfunctions,” he says proudly. Since the implementation of the most recent standard, Berzelius has had a solid basis for the continuous im-provement process. An energy fl ow diagram shows the energy distribution across the entire production process, so that energy fl ows such as gas and electricity can be allo-cated to the functional areas and processing

INFORMATIONAlexander Pauluschpaulusch@de.tuv.com +49 2161 822 164 www.tuv.com/energy-management

stages better controlled. The balance sheet after the implementation of the DIN EN ISO 50001 standard is just as impressive as the purity of the STOLBERG lead: Berzelius has been able to save up to 66 percent of energy consumption in individual process steps, reduce its CO2 emissions considerably and improve its energy balance by three percent annually. In addition, BBH has optimized the processes in extracting silver from lead, invested in modern aggregates and reduced the burner capacity by one third. The results are remarkable: Specifi c energy consump-tion values have been halved and the cost structure in manufacture improved, while maintaining the same level of product qual-ity. The annual target is still three percent in energy savings. This corresponds to a reduc-tion of about 9 GWh each year. “At some point we have to draw a line,” says Heiko Ambroz. “There will come a time when we won’t have any more room for improve-ment processes if we want to maintain our standards. Until this time comes, however, our efforts are paying off.” Berzelius Stol-berg is predicting approximately EUR 1.8 million in savings for 2013 alone. «

Berzelius energy management Regions 29contact 3.13

THE MOST IMPORTANT LEAD PRODUCING COUNTRIES

Lead is booming:

10.6 million tons were

extracted in 2012.

Potential for huge

energy savings.

Et ullorem quisinus

moloreped eaqui

acepuda velles modi

dolupta conet offi cta

conCommoluptat.

WE PROMOTE IMAGINATION AND CREATIVITY

People Playmobil makers30 contact 3.13

Et ullorem quisinus

moloreped eaqui acepu-

da velles modi dolupta

conet offi cta con

Ms. Schauer, four out of ten products sold by your company are new developments. Where do all the new ideas come from?The ideas for the over 100 new Playmobil products we launch each year come from our in-house Develop-ment department with nearly 80 staff members and the interaction between the Marketing, Sales and Export divisions. It is particularly important to listen to our target group – children – and to know what they get up to every day. This is why we take the feedback, children give us, very seriously. After all, children are the ones who have to like our products.

What has been especially popular among children recently?Of course, the Christmas market is crucial to the toy in-dustry. Playmobil Advent calendars, the horse farm and the hotel, for example, were among the top 50 items in the traditional toy market in 2012. The cool Asian drag-on land and the shopping center with new exchange-able clothing to dress up the fi gures are very popular this year.

In spite of all the innovations, the fi gures themselves have hardly changed since the early 1970s.The basic fi gure has defi nitely stayed the same, in terms of its likable overall look and typical face. But a lot has changed, too. For one thing, technical developments since 1981 have made it possible to injection mold

the hands and arms in a range of different plastics and colors, in addition to making the hands rotatable. For another, the Playmobil play worlds have become more sophisticated and diverse – and so have the fi gures. That said, nothing has changed with regard to the plastic we use. Here we paid close attention to quality and maxi-mum safety from day one.

How environmentally friendly are plastic toys?We see Playmobil as a sustainable toy on the whole. Our owner, Horst Brandstätter, always stresses that “Play-mobil is never thrown away; it is sold on to the next generation at fl ea markets or stored in the attic for years to come.” When it comes to the manufacturing process, we take great care to conserve resources and use energy effi ciently. It is not without reason that we successfully achieved certifi cation for our environmental manage-ment in 2011 and are now working towards implement-ing an energy management system.

What are the most important markets for you?Our most important foreign market is France. I believe Playmobil is just as well-known and popular there as it is in Germany. Europe as a whole is our biggest market.

What role does toy testing play in your success?The topic of quality and safety has always been our top priority. And we’re noticing that parents, too, are more and more concerned about the issue of toy safety. ›

ANDREA SCHAUER, CEO OF PLAYMOBIL MANUFACTURER GEOBRA BRANDSTÄTTER, ON QUALITY AND INNOVATION, THE MOST IMPORTANT MARKETS AND UNSEEN LEARNING ACHIEVEMENTS.

They check everything

from top to bottom.

But quality fanatics they

are not: the testers at

TÜV Rheinland. Their

job is stressful yet

highly interesting.

Playmobil makers People 31contact 3.13

english

Though not legally required to do so, we see it as our duty to ensure that we have our materials, colors and fi nished products tested by an external partner, TÜV Rheinland, and have been doing so since early 2000. A fact that is appreciated by retailers and customers alike.

Talking about southern Europe, you once said that “Children are still allowed to play freely there.” Do we in Germany not give our children enough freedom to play?Playmobil is for creative role play – and the crazy thing about it is that children enjoy role play and learn a lot from it at the same time. Adults

cannot see or measure this learning achievement at fi rst, however. In Germany, we tend to want results right away.

What Playmobil achieves is at fi rst invisible and takes place within the minds of children, and may only manifest itself when they have grown up and are particularly good at solving problems using their creativity and imagination. I believe we should give children the time to play freely because it is good for their souls and therefore for our society. «

contact 3.13

ANDREA SCHAUERAndrea Schauer has been CEO of geobra Brandstätter GmbH & Co. KG since 2000 and is responsible for the Development, Marketing and Sales divisions. She started her career at Playmobil in adver-tising and PR. geobra Brandstätter GmbH is the manufacturer of Playmobil and therefore the largest toy producer in Germany. Over 2.6 billion Playmobil fi gures have been manufactured since 1974. The Brandstätter Group employs more than 3,700 people worldwide.

People Playmobil makers32