ODE is a rapidly growing company and one of its latest developments is a new 75,000 sqm facility, incorporating a 70,000 sqm manufacturing space at Eskisehir in northwest Turkey and is currently the world’s third-largest rubber foam manufacturing plant.
Challenge:
The plant processes include extruded polystyrene thermal insulating materials, polymer-modified bituminous waterproofing blankets, glass wool products used for heat and sound insulation and fire safety, and elastomeric rubber foam insulating material. These processes involve combustible materials and part of the foam manufacturing process also includes ovens in which oils are heated to over 225° Celsius. Efficient fire precautions are of paramount importance. As Turkey’s fire regulations cover just a base level of protection, ODE sought advice from various professionals on full fire protection for the plant, including Johnson Controls. Johnson Controls’ solution meets stringent safety audits and makes it easier for ODE to obtain building and contents insurance.
Benefits at a Glance
• Has the flexibility to support business expansion
• Provides quick and reliable fire detection
• Reduces the capital cost of equipping new buildings
• Exceeds national fire regulations and meets local fire audit demands
• Safeguards people and property
Profile
Founded in 1985, the Turkish company, ODE, is one of the world’s largest insulation manufacturers. It has five state-of-the-art facilities and exports to five continents. Producing more than 4,000 products, it concentrates on two main categories: providing insulation for buildings and for heating and ventilation and air conditioning (HVAC) systems.
Scope of Work
ODE is a rapidly growing company and one of its latest developments is a new 75,000sqm facility, incorporating a 70,000sqm manufacturing space at Eskisehir in northwest Turkey. With 300 staff, this is currently the world’s third-largest rubber foam manufacturing plant. Processes include extruded polystyrene thermal insulating materials, polymer-modified bituminous waterproofing blankets, glass wool products used for heat and sound insulation and fire safety, and elastomeric rubber foam insulating material. These processes involve combustible materials and part of the foam manufacturing process also includes ovens in which oils are heated to over 225° Celsius. Efficient fire precautions are of paramount importance.
Turkey’s fire regulations cover just a base level of protection and so ODE sought advice from Dr. Kazim Beceren of ETIK, Turkey’s most prominent fire protection consultancy. He compiled a risk assessment and advice on the precautions that should be in place. ODE asked Johnson Controls to suggest protection products that were appropriate for the risks and it then issued a tender. “We considered three companies and the specialist consultant advised us that Johnson Controls would be the best solution for us, not only because of the standard of its equipment but
also because of its market experience,” says Aydin Murat, Business Manager, ODE. “He gave very positive feedback on the company’s product portfolio and its capabilities and so we decided to go with Johnson Controls for our fire detection system.”
Solution
The ODE system includes 150 smoke detectors, 150 control modules, and 30 alarms and beacon units. Everything is monitored and controlled by ZETTLER Profile Series touchscreens. One is situated in ODE’s main building, with the second one in its security building. Two wiring loops cover the main factory and a third loop covers a 600sqm mobile office area, that was added as part of expansion plans. Following trials, the Johnson Controls detection system works well with the third-party fire suppression sprinkler system, which includes: one diesel, one electrical pump, and a 1,000-ton water tank. “From the touch screens, we can control every single part of the fire suppression system, right down to the valves,” says Murat. “Our HVAC system is also
controlled by the solution because in the event of a fire we need to extract smoke as quickly as possible. If the Johnson Controls system detects a fire it automatically takes control of the HVAC systems to extract all smoke from the building.”
Benefits
Evotek, a ZETTLER-approved system integrator, provides 24×7 support and short lead times if products need to be changed or added. Also, if any detectors need to be tuned or adjusted, this can be done remotely.
ZETTLER is part of Johnson Controls and since its touchscreens can control up to 16 high-powered wiring loops and 4,000 devices, they deliver significant cost advantages by minimizing additional hardware expenditure during factory expansion. The flexibility of the Johnson Controls system also delivers significant advantages with additional loops easily added when new buildings are commissioned. The respected name of the fire consultant combined with the Johnson Controls brand has made it easier for ODE to obtain building and contents insurance. Also, the building is in a highly efficient industrial zone which carries out its own audits of tenant companies, and the Johnson Controls system makes it easier for ODE to satisfy these stringent audits.“ With Johnson Controls, I have confidence that our building is well protected and that brings peace of mind,” concludes Murat. “For us, it is important that we can get support and products whenever we want.
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