On the Path to Sustainable Aircraft Production – Packing Efficiency in a Suitcase
The CTC manufacturing hall, Photo: CTC
"Design for Efficiency" is about creating systems that not only fulfill their purpose but also consume as little energy as possible. In aircraft manufacturing, ECOMAT partner Composite Technology Center (CTC) is pioneering new ways to optimize today’s factories and make tomorrow’s factories more energy efficient.
Efficiency is paramount in aircraft production—both in-flight operations and factory production. Processes are continually optimized to develop better materials with fewer resources while maintaining high safety standards. But saving resources isn't just about using innovative materials; it also means optimizing existing processes to reduce energy consumption. In a complex factory environment, machines are interlinked; turning off one device might cause issues elsewhere or require a complex startup process.
"This brings us to the key question: how much energy do we need at each point to add value, and how can we optimize processes accordingly?" asks Jan Ohm, project manager at CTC. Together with fellow project manager Jannis Eckhoff, they form a sustainability team focused on examining manufacturing processes to identify where energy can be saved without impacting the overall system.
The Composite Technology Center (CTC GmbH) is a wholly-owned subsidiary of Airbus and operates as a lightweight technology center in Stade, with offices in Bremen’s ECOMAT technology center. It develops lightweight technologies and solutions for the aerospace industry and over 100 clients worldwide across various sectors. The CTC specializes in prototyping, test part production, and professional composite manufacturing training. As an ECOMAT partner, it especially focuses on future aircraft manufacturing methods.
The energy measurement case, Photo: CTC
The case allows measurements to be taken without interrupting ongoing operations, Image: CTC
On-the-Go with Portable Measuring Electronics
They have a trick up their sleeve—quite literally. The "PERU Portable Energy Recording Unit" is a measuring kit equipped with sensors for compressed air, electric energy, and more. It can record up to 15 electric measurement points simultaneously without modifying the ongoing production in a plant. "We can measure the entire current of a machine, such as a heater, without needing to change the equipment," says Ohm.
Developed by CTC in collaboration with Airbus colleagues as part of CTC student Florian Kohne's engineering thesis, the measuring kit and analysis process have been nominated for the JEC Innovations Award 2024—a recognition the team is proud of. An improved version is set to be implemented next year at the Hamburg plant.
The collected data enables energy simulations and optimization of processes based on energy consumption. This helps improve current factories and future production processes. "With the insights we gain, we can recommend energy-efficient processes and hardware, as well as necessary sensors and data interfaces. It’s better to plan a system efficiently from the start than to retrofit it later," Eckhoff explains.
Life Cycle Assessment (LCA) in Aircraft Manufacturing
The team’s capabilities are well-regarded within CTC and Airbus. They’ve also been active in Bremen, collecting data for life cycle assessments of thermoplastic, fiber-reinforced plastic parts. These insights are crucial for developing future products. LCA data help the Airbus LCA team realistically model part production. "Holistic product consideration is becoming increasingly important. We need to think about sustainability from start to finish," adds Ohm.
Jan Ohm
Jannis Eckhoff
Part of the ECOMAT Research and Technology Center
The energy measurement kit is just one of many sustainability initiatives at CTC, where they’ve long focused on material recycling and generating new ideas. In addition to energy tracking, they aim to establish systems that monitor and optimize energy and material flows, minimizing waste and conserving resources. "This brings us closer to comprehensive sustainability in production," says Eckhoff.
And not just in Stade or Hamburg—of the 60 CTC employees, a dozen regularly work in Bremen at ECOMAT. Bremen native Jan Ohm values this collaboration, not only because he can work in his hometown: "We have strong connections to CFK manufacturing, Airbus plateaus like Materials & Processes and Research & Technologies, and other ECOMAT partners, such as the Bremen Fiber Institute and TESTIA. This network is incredibly valuable and helps us develop the right technologies for complex, interconnected aircraft production."
