Industry and engineering

How high is your lighting system's optimisation potential?
zumtobel.com/industriallighting

Industry and engineering

References

Industry and engineering

Increasing automation brings fast, precise workflows, and the requirements placed on activities that involve demanding craftsmanship are becoming more exacting. A space needs to cater for a variety of usage scenarios and requirements in order to take both these aspects into account. Different ceiling heights, temperatures and degrees of automation demand functional flexibility. Not only that, industrial architecture and the image that industry seeks to project are witnessing radical change.
Sustainable production technologies are becoming increasingly important in almost all industries worldwide. Companies are putting in place measures to increase resource and energy efficiency and also to optimise production processes, procedures and energy sources. Industrial applications have huge potential in environmental and economic terms and when it comes to human factors.
Flexibility
Efficiency

Industry and engineering

Whereas in some industrial enterprises extreme temperatures, humidity and vibration represent major challenges, in other companies extreme precision or conscientious attention to hygiene is the order of the day. The measures to ensure maximum reliability are as different as the industrial facilities themselves. The lighting should work at all times regardless of environmental influences, including during power cuts.
Economic conditions demand production increases, more efficientworkflows, improved organisational structures, technological progress and as few faults as possible. Productivity is a long-established concept but is only now giving rise to a complete rethink in many industries. Nowadays, more capital and labour are being invested in optimising productivity from the ground up.
Reliability
Productivity

Industry and engineering

Calculating the potential

The lighting in many industrial facilities is not state-of-the-art. However, employees are still expected to give their best, which under the given circumstances can be either impossible or else very difficult. With innovative luminaires and a professional lighting control system, however, lighting can become a factor that adds value. The best light for industry is:
  • Light that consumes fewer resources but provides higher output
  • Light that responds to changes
  • Light that improves an inividual’s performance and enhances their wellbeing
  • Light that works safely and reliably for many years
With the Zumtobel lighting analysis tool, you can see in a few minutes the potential that a new lighting system would open up for you. The analysis results are concrete numbers that answer pertinent questions about energy consumption or CO2 emissions, such as "How much can I save?", "Where do the savings come from?", or "What potential does a lighting control system have?" The second area of the analysis refers to the flexibility of the lighting. "Where would it be advantageous to respond flexibly to varying requirements, visual activities or occupancy times?" The third level is that of productivity. Increases can be achieved, particularly in areas where repetitive manual work is performed. Factors such as the wellbeing and sleep quality of employees are just as relevant as the speed at which tasks are performed. These are influenced by the proper selection of light colour and by dynamisation of the lighting. The fourth point to consider is the potential for reliability compared to the existing system. You will be shown the percentage by which reliability can be increased by lighting that takes account of specific environmental conditions and carries on operating even in emergencies.
Step one: record the core data for the project and area of application.
Step two: enter the data on the existing lighting system and technologies employed.
Step three: define the zones, their dimensions, visual tasks and ambient conditions.
Result: you will immediately be given a clear overview of the potential of a new lighting system. The PDF version contains all the interesting details as well.
The Zumtobel lighting analysis tool will evaluate your current lighting situation and calculate the potential for refurbishing the lighting in the four core areas: CO2 and cost efficiencies, flexibility, productivity and reliability.

You can perform the calculation on-line at the Zumtobel website at any time. It only takes a couple of minutes to fill it in, and the results are displayed directly on-line and also output as a comprehensive PDF document.

zumtobel.com/industriallighting 
BEFORE
AFTER
Lighting analysis tool

Industry and engineering

Efficiency

"At EnBW EnergyWatchers we have made it our mission to help small and medium-sized enterprises save energy costs. We are efficiency professionals and are able to tap into potential savings in companies and help them make savings while also benefiting from public funding. We need capable, dependable partners by our side in order to be able to improve customers’ competitiveness in this way. Zumtobel’s unique lighting expertise enables us to implement our ideas when it comes to efficient lighting. This allows our customers to cut their long-term energy costs while also protecting the environment."

Melanie Bunke
Executive Board, EnBW EnergyWatchers GmbH | DE
Recommended products:
VALUEA | high bay reflector luminaire
PST presence detector | lighting management system
  • Saving energy is not simply a matter of cutting electricity costs, it also means optimising a company’s CO2 budget
  • Industrial plants can make a significant contribution towards helping the country in which they are located achieve a successful CO2 balance
  • CO2 certificates spell out the fact that an entrepreneur is conscious of his or her responsibilities
Calculation example: Investing in a lighting solution using GRAFT high bay LED luminaires rather than metal halide lamps (HIE) pays for itself within two to three years. Power consumption per square metre per year is cut by 55% using modern LED technology. An additional presence-based and daylight-based control system for the bay with a sawtooth roof reduces energy consumption to a striking 78%.
Scania Parts Logistics, Opglabbeek | BE
Comparing various lighting concepts, calculating total costs and payback times: ecoCALC design software makes it possible to check out the sustainability of lighting solutions and refurbishment projects quickly.

Technogym SpA, Cesena | IT Cesena

 

 

Recommended products:
LUXMATE LITENET |
lighting management system
LUXMATE external daylight sensor | sensor
  • Sightlines into manufacturing workshops and workflows differentiate and position a company
  • Extensive glazed surfaces provide a reference to outward reality but also require architecture-related lighting
  • Contemporary lighting solutions enhance the image of both the architect and the company as a brand
Bosch Rexroth, Pasching | AT
Recommended products:
TECTON LED | continuous-row luminaire
LUXMATE LITENET | lighting mangement
system
  • Refurbishing an out-of-date lighting solution has a positive impact on energy consumption, working atmosphere and operating costs
  • Modern lighting solutions reduce expenditure on maintenance and improve lighting quality
  • LED lighting and lighting control systems are an investment in the future
Introduction
Cutting CO2 emissions
Reducing energy consumption
ecoCALC design software
Use of daylight
Replacing lighting systems

Industry and engineering

Example for refurbishment

38 % lower annual energy consumption

22.27 kWh/m2 Existing lighting installation
13.87 kWh/m2 New lighting solution using TECTON 2/49 W
                            with LUXMATE LITENET lighting control system
                            and ONLITE emergency lighting system 

The flexible TECTON trunking system ensures bright ambient lighting and comfortable working conditions. A lighting control system adjusts the artificial lighting depending on the amount of daylight that enters through the skylights. This enables Bosch Rexroth to save up to 22,240 kWh of electricity per year. Its investment will be amortised in less than 4 years.

Bosch Rexroth, Pasching | AT
After refurbishment

Industry and engineering

Flexibility

"The lighting played a major role in the design of our new company headquarters. Zumtobel has managed to perfectly meet our requirements in terms of superior lighting in a variety of rooms. Zumtobel has turned out to be an indispensable partner, supplying a professional and energy-efficient lighting solution for the single-person offices, the conference room and manufacturing through to components assembly."

Erich Gummerer
CEO TechnoAlpin AG, Bolzano | IT
Recommended products:
CHIARO LED | moisture-proof luminaire
LUXMATE | presence detector
  • Visual requirements specific to individual operations are ideally met by variable light focussed on the task area.
  • Rising efficiency and increased automation are making new demands on lighting
  • Good light caters for people’s individual requirements, visual tasks and eyesight
Rema Holzindustrie, Eben im Pongau | AT
Mondelēz Belgium Biscuits Production NV, Herentals | BE

Recommended products:
DIMLITE | lighting management
LUXMATE LITENET | lighting
management system

 

  • The flexibility requirements on lighting increase with shorter product cycles and increasing product diversity
  • The big benefit of lighting management systems: there is no need to change the lighting installation, the adjustment is done by computer
  • Well-trained Zumtobel service personnel take care of design, commissioning and also maintenance if required
Hörmann Austria Ges.mbH., Dobl | AT
Recommended products:
TECTON LED | continuous-row luminaire
GRAFT | high bay LED luminaire
  • The trend is for higher bays with high visual requirements
  • Linear solutions with fluorescent lamps and innovative high bay LED luminaires provide impressive uniform illumination with dimmability and controllability.
  • LED solutions boast a long service life, full output in cold environments, and the capability for integration into emergency lighting systems
Schletter Leichtmetallbau GmbH, Kirchdorf | DE
Recommended products: 
PANOS INFINITY | LED downlight
LIGHT FIELDS LED | recessed luminaire
  • Different applications that make different demands on lighting are mixed up in industrial buildings
  • Taking into account circulation routes, workflows and areas of activity throughout an entire building makes orientation easier
  • A lighting solution and lighting control system that take a cross-building approach use light in a targeted manner, thus reducing expenditure on energy
Introduction
Preserving individuality
Changing structures
Coping with long distances
Holistic planning

Industry and engineering

Productivity

"Production work often involves shift work. Nowadays it is taken for granted that shift work has a negative impact on the risk of accidents and sleep quality. Room lighting can have a positive effect, especially in times when work-related stress is increasing due to an arrhythmic lifestyle. A "productive" lighting solution meets both visual and biological needs. Such lighting solutions often include a lighting control system that varies the intensity of light and light colour based on specific working hours and shift models." 

Markus Canazei
Bartenbach LichtLabor GmbH, Aldrans | AT
Flextronics, Althofen | AT

 

 

What influence does dynamic lighting have on the well-being of employees who work shifts? To answer this question, Zumtobel relies on scientific research, either directly in the field or in the laboratory. The study results show that dynamic light has a demonstrably positive effect on productivity by reducing physiological strain and improving performance. As a less costly alternative, high-frequency dynamic lighting can increase activity and reduce the stress factor.
Recommended products:
TECTON LED | continuous-row luminaire
LUXMATE EMOTION | lighting management
  • Lighting design concentrates on accomplishing visual tasks without making mistakes
  • Smaller details are more visible with high illuminance levels, and the number of accidents decreases
  • Pleasant distribution of luminance levels in a space, and a balanced mix of directional and diffuse light enhance visual comfort

Ferrari S.p.A., Maranello | IT

Recommended products:
TECTON LED 6.500 K | continuous-row luminaire
LUXMATE LITENET | lighting management system
  • Light affects an individual’s natural circadian rhythms and prevents fatigue
  • Light with short-wave blue spectral components stimulates, while warm white light has a relaxing effect
  • Light whose colour temperature changes dynamically has a positive influence on people’s health
Ferag AG, Hinwil | CH
Recommended products:
GRAFT 6.500 K | high bay LED luminaire 
SCUBA 6.500 K | moisture-proof diffuser luminaire

 

  • Natural daylight has very special qualities and everyone perceives it as being pleasant.
  • Cool white lighting in an interior enhances the natural effect of light and avoids mixed-lighting situations.
  • Cool white LED luminaires combine visual comfort with almost unparalleled efficiency.

Alpla Werke, Hard | AT

Recommended products:
TECTON LED | continuous-row luminaire 
LUXMATE LITENET timeline editor |
lighting management system

 

 

  • Light for people that promotes both wellbeing and motivation can only really be achieved by using a lighting control system
  • Timelines are used to implement a wide variety of individual project requirements
  • Graphic editors are simple to use and are an important tool in utilising the advantages of dynamic lighting in in everyday situations

Mondelēz Belgium Biscuits Production NV, Herentals | BE

Introduction
Researching the effects of light
Optimising visual performance
Supporting biological rhythms
Daylight as a model
Intelligent control

Industry and engineering

Reliability

"In industry, the requirements in terms of lighting for workstations have increased over the past years. Optimal lighting today is characterised by customised innovative lighting technology integrating the amount of daylight available. The proper arrangement of luminaires, as well as the efficiency and cost-effectiveness of luminaires and lamps play an essential role in this respect. The choice of luminaires depends on ambient conditions – difficult at times –, such as room height, ambient temperature and dirt load. In order to provide for easy cleaning of the luminaires and smooth replacement of lamps, we attach great importance to good accessibility and easy handling."

Heribert Czarnetzki
Master Electrician Otto Fuchs KG, Meinerzhagen | DE
Recommended products:
TUBILUX LED | tubular LED luminaire
KXB 2 LED | explosion-proof luminaire 

 

 

  • Bright environments with bright vertical surfaces make it possible to take in an entire room at a glance, thus creating a feeling of greater safety
  • Environmental influences dictate the protection rating of a luminaire
  • Explosion-proof luminaires ensure safety in industrial locations where harmful dust or gases are liable to occur

APAG Parkhaus Aachen | DE

Recommended products:
SCUBA LED | poisture-proof diffuser luminaire 
CLEAN LED | clean-room luminaire
  • Cleanliness and hygiene are promoted by bright, low-maintenance,easy-to-clean lighting systems
  • Cleanliness during manufacture is becoming more important as increasing demands are placed on product quality
  • Difficult visual tasks such as precision inspections or wiring are made easier by good lighting and a clean environment

Pasticceria La Baita srl, Caselle Torinese | IT

Recommended products:
METRUM | continuous-row system 
ONLITE RESCLITE | emergency luminaire
  • Maintenance is a crucial factor in high bays and in situations where luminaires are hard to access
  • State-of-the-art LED solutions have the advantage of long service lives
  • In contrast, LED retrofit lamps often involve excessive compromises when it comes to lighting quality, technical safety and energy efficiency

Freitag Taschen, Zürich | CH

Recommended products:
ONLITE RESCLITE for greater heights |
LED emergency luminaires 
CROSSIGN 160/110 | scape sign luminaires 
ONLITE CENTRAL eBox | emergency lighting
supply system

 

 

 

 

 

 

  • LED emergency luminaires with extra protection tailor-made for industry and especially for high ceilings
  • Wide selection of escape sign luminaires with low-cost all-round models for industry
  • Flexible and modular emergency lighting

Rema Holzindustrie, Eben im Pongau | AT

Introduction
Increasing toughness
Maintaining cleanliness
Simplifying maintenance
Increasing safety in emergencies

Industry and engineering

Specimen solution for a production bay

Electronic components are produced, packed and stored in an area of 1,200 square metres in this specimen bay. The height of the space is six metres, and daylight enters along a window frontage on one side and through skylights. The bay was lit by HID reflector luminaires prior to refurbishment. The comparison with a lighting solution using VALUEA T16 high bay reflector luminaires and another LED lighting solution with GRAFT and LUXMATE LITENET clearly shows the potential of an innovate lighting solution.

Industry and engineering

Lighting analysis

CO2-emissions over service life (20 years)                                                             Development of total costs over service life

Industry and engineering

Lighting analysis

Flexibility                         Productivity                       Reliability 

 

CO2-emissions

 

 

1. CO2 and cost efficiencies   The existing lighting solution consumes 93.5 kWh of power per square metre and year; the GRAFT LED lighting solution, however, which is controlled by LUXMATE LITENET, consumes only 26.88 kWh. This corresponds to a reduction by 71 percent, with the lighting control system accounting for some 48 percent. The alternative solution using T16 high bay luminaires reduces energy consumption by 13 percent.

2. Flexibility   The illuminance level is 750 lux throughout the bay, designed to meet the very demanding visual tasks in the production area. The ability to reduce the lighting level to 300 lux at the packing station and to 150 lux in the finished goods warehouse reduces unnecessary energy consumption and provides flexibility.

3. Productivity   The lower the illuminance level of ambient lighting, the higher its factor for additional motivation. By increasing the lighting level by 12 percent in the warehouse, by 10 percent at the packing station and by 5 percent in the production area, productivity is increased by an average 8 percent.

4. Reliability   The fact that the luminous flux of a GRAFT luminaire does not decrease even in case of high temperatures below the bay’s ceiling makes the lighting all the more reliable. Another important aspect is the high bay LED luminaire‘s low failure rate, which results in less frequent downtimes and lower maintenance costs.

zumtobel.com/industriallighting

Industry and engineering

Learn more about Industry and engineering
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References

Construction of Hall 100, VW Motor Works
Chemnitz, Germany
Owner: Volkswagen AG, Wolfsburg (DE)
Architect: IC-L Ingenieur Consulting Langenhagen GmbH & Co. KG Langenhagen (DE)
Lighting design: Volkswagen AG, Wolfsburg (DE)
Electrical consultants: Volkswagen Elektroplanung, Wolfsburg (DE)
Electrical installations: Voith Industrial Services GmbH, Chemnitz (DE)
“From product to factory” was the planning principle at Volkswagen. Because the developments in innovative and ecofriendly motor technology at VW during the past years will also be implemented in the architecture of the production plants in the future. The goal is to become the world’s most eco-friendly automobile manufacturer by the year 2018. The construction of the new Hall 100 of the Chemnitz Motor Works has brought the company one step closer to this goal.

In November 2013 the project was awarded the gold certificate of the German Society for Sustainable Construction (DGNB). The new hall therefore meets the stringent criteria of the DGNB, which is based on a comprehensive consideration of economy, ecology and user convenience.

According to the motto “More sustainability, less environmental impact” various workshops have been established in Chemnitz to intensively strive for ways to reduce energy consumption. A comprehensive analysis of the production process is the key to this endeavour. Above all, the production systems are analysed based on energy efficiency to make use of every potential for optimisation. The lighting system with innovative LED technology makes a major contribution in this respect.

In the mechanical production  process, high-tech machining centres and complex, virtually fully automatic line controllers define the production process. This requires homogeneous illumination with an average of 300 lux. Another requirement was dimmable luminaires and integration of emergency lighting in the continuous row lighting. Zumtobel was able to optimally fulfil all of these requirements with the TECTON LED continuous-row lighting system and integrated emergency luminaires. DIMLITE modules ensure efficient control of the continuous row lighting.

Zumtobel. The Light.

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Lighting solution
Ferrari Classiche
Maranello, Italy
Owner: Ferrari s.p.a., Maranello (IT)
Architect: Arch. Simona Franci, Fortebìs Group, Rome (IT)
Lighting design: Arch. Francesca nasi, Carpi (IT)
Electrical consultants: Prospazio, Modena (IT)
The former foundry is now a combination of car workshop, laboratory and museum. Historic sports cars are inspected, appraised, repaired and then handed over to customers on these premises, which cover an area of 950 m². Daylight that shines down through the glazed roof, a daylight-based control system and a TECTON LED continuous-row lighting system guarantee high lighting levels with maximum efficiency. Within the next 20 years, more than 500 tonnes of CO2 will be saved thanks to this refurbishment.

Daylight, a high lighting level of 1000 lux and an intermediate light colour of 4000 K aid productivity by perfectly meeting the demands for meticulous small detailed work. The general dimmability of LED luminaires makes it easy to adjust the lighting to cope with various activities and usage periods. This extra reliability is achieved thanks to the LED's long service life and IP50 rating. Emergency lighting has been integrated into the general lighting system. Every third TECTON LED is an emergency luminaire.

Zumtobel. The Light.

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Lighting solution
Technogym spa
Cesena, Italy
Owner: Technogym spa, Cesena (IT)
Architect: Antonio Citterio Patricia Viel and Partners, Milan (IT)
Lighting design: Antonio Citterio Patricia Viel and Partners, Milan (IT)
Electrical consultants: Studio R.B. Engineering, Modena (IT)
Electrical installations: F.lli Franchini, Rimini (IT)
At the very time when Sylvester Stallone and Arnold Schwarzenegger were showing off their muscles on the silver screen, a success story was also in the making in Italy. What the then 22-year-old Nerio Alessandri invented in his garage, however, was neither a computer nor a sports car. With the “Asterisco” model, the trained mechanic assembled the first home training machine with a design that did not clash with ambience of a living room. “Technogym” was the name given by Alessandri to his start-up, which he established in Cesena, near Rimini, in 1983. While he originally organised sales via the local phone booth, such temporary solutions have long
been superseded. Today, the company has 2,200 employees and it’s products can be found in 50,000 fitness studios and more than 30 million private households throughout the world. This development is the result of a far-sighted realignment: in addition to muscle building, the machines were to fulfil the purpose of boosting well-being. Since then, the idea of wellness has led to product developments for which scientists from MIT and other experts are often consulted. Also, the company headquarters in Cesena, which opened in 2012, is anything but a normal factory with an adjoining administrative building. Only a few kilometres from Nerio Alessandri’s old garage now stands a “Wellness Campus”, where products are produced, researched and discussed, with no small amount of perspiration. “We are not only a manufacturer of sports equipment, but also a service agency,” says Roberto Laureti, the technical manager responsible for building control and maintenance at Technogym. About 25,000 visitors are received every year on the 150,000 m2 company grounds, which includes a research center, a library, a fitness club, a health food restaurant and a conference center with 600 seats. Several hundred courses are offered – from classic training for sports trainers to motivation and leadership training for managers.

The task faced by the Milan-based architect Antonio Citterio and his partner Patricia Viel was as follows: To translate wellness into a structural framework that combines sustainable, eco-friendly construction with a high quality of well-being. That no ordinary assembly hall is to be expected here is immediately apparent. The 60,000 m2 building is situated in the midst of a rolling park landscape and is crowned by a wave-shaped curved wooden roof. “The architecture plays a crucial role in the light planning,” Roberto Laureti emphasises. The entire building is divided into eight segments, each with a width of 18 m and a length of between 200 and 280 m. Seven segments combine to form the 32,000 m2 production hall and warehouse, where assembly of the machines takes place. Continuous row lighting suspended from the ceiling extends the entire length of the hall, providing a brightness of 390 Lux for the assembly area. In the storage areas, located upstream and downstream of the production area, the brightness is reduced to 150 Lux. Sensors are used to adapt the intensity of the lighting based on the daylight conditions. The skylights, which follow the wave shape of the roof, ensure that even the middle of the hall is flooded with sunlight. In the afternoon hours and on overcast days the intensity of the artificial light is adapted to the reduced natural light, to create a constant perfect interplay of the two light sources, for well-balanced and pleasant lighting of the production hall.

The production area is separated from the 11,000 m2 administrative building by a road flanked with trees. The slight curve of the wooden roof on the south side of the four-story building has a dual purpose: it not only provides an inviting gesture for arriving visitors, but also protects the fully windowed offices against direct sunlight and overheating. The offices are characterised by openness. The conference rooms, which have windows on all sides, feature round bean bags as seating for employees and guests, and the workplace is designed as an “open space” office. Narrow continuous row lighting accents the room, providing a colour temperature of 2,700 K for a warm, pleasant atmosphere. The elliptical “Wellness Center” in the south end of the administrative building houses the public functions of the campus on an area of 4,000 m2. To enter this area, visitors must first descend a spacious spiral staircase that winds through the entire building. While the wooden steps give a down-to-earth appearance, the impression on the bottom side is much different. Together with Zumtobel, Antonio Citterio and Patricia Viel developed a backlit LED solution to create changing colour and light moods. The southern part of the ellipsis houses the fitness centre, which also serves as a showroom for Technogym products. This room, which is flooded with daylight, opens onto the surrounding park with a glass curtain façade over two stories. All of the employees can exercise here during the week, and on weekends their families and friends can use the facilities free of charge.

The company also insists on balanced nutrition for the employees. The restaurant’s cooks use only seasonal vegetables from the surrounding region. Chocolate bars, on the other hand, have been banned from all vending machines. Instead, they are filled daily with fresh salads, fruits and other healthy snacks. The “wellness system key” prevents anyone from exceeding their personal limit. This data storage system records the training results and calculates the calories burned so far on a given day. With each fruit salad from the office vending machines, the number rises, providing a discreet recommendation for more exercise. By now it should be clear: Wellness in Cesena is not an activity that lasts only a few hours. It is an attitude that encompasses one’s entire life.

Zumtobel. The Light.

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Lighting solution
Risse + Wilke Kaltband GmbH & Co.
Iserlohn, Germany
Owner: Risse + Wilke Kaltband GmbH & Co., Iserlohn (DE)
Electrical consultants: Mark-E, Hagen (DE)
Lighting refurbishment yields energy savings of up to 45%

Metal halide lamps were previously used in cold-rolled steel strip producer Risse+Wilke’s manufacturing bay. However, this outmoded, conventional way of producing the quantities of light needed in large, tall industrial buildings does not stand a chance up against modern lighting solutions in terms of quantity or quality. Modern lighting solutions help optimise conditions at the workstations, improve motivation and prevent fatigue, therefore reducing industrial accidents. This is why the cold-rolled steel strip producer decided to modernise the lighting installation in its production plant by installing new high-bay reflector luminaires.

The 545 new VALUEA high-bay reflector luminaires are fitted with state-of-the-art fluorescent lamps and high-performance reflectors. Their premium lighting quality is confirmed by an excellent colour rendition index > 80 and now more uniform illumination. Luminous flux is virtually constant and even ambient temperatures of 35 °C are no problem. The use of advanced, controllable ballasts is a crucial aspect of this high energy efficiency. Dimming alone cuts energy consumption compared with a non-dimmable lighting solution by 30% and daylight-based lighting management increases potential savings further still. Flicker-free light is an additional benefit when using rotating machinery. Unlike conventional high-bay projectors that use 50 Hz technology, fluorescent lamps operate at 22 kHz, thus preventing any strobing.

Risse+Wilke now consume up to 45% less energy after completing their lighting refurbishment project and installing VALUEA and a DIMLITE lighting management system. This simple plug-and-play system makes commissioning much easier: with DIMLITE, the required components are simply hooked up to a base module and started up by an auto setup procedure. The required group control was also implemented straightforwardly so that individual sets of luminaires can be dimmed individually or depending on the amount of daylight available. The fact that lighting control now makes it possible to respond flexibly to changes in the layout of the storage or production area is yet another benefit.

Zumtobel. The Light.

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Lighting solution:
Alexander Bürkle GmbH & Co.KG
Freiburg, Germany
Owner: Alexander Bürkle GmbH & Co.KG, Freiburg (DE)
Architect: Freyler Industriebau GmbH, Kenzingen (DE)
Electrical consultants: Planungsgruppe Burgert, Schallstadt (DE)
Electrical installations: El. Geppert, Breisach (DE)
Two applications, one solution

Alexander Bürkle GmbH have extended their site by building a 2,600 m² warehouse and an adjacent office building. As a participant in Freiburg’s ECOFIT promotion scheme, this Freiburg-based electrical wholesaler seizes every opportunity to ensure environmentally compatible and economically efficient operation by using the very latest technologies. Zumtobel’s innovative lighting concept is making a valuable contribution towards achieving the goal of reducing energy consumption without compromising excellent lighting quality.

The architecture of the new three-storey administrative building was ideal for exploiting the benefits of LEDs. The office premises were built without any columns or supporting elements to ensure flexible floor space usage. Zumtobel developed an equally modern office lighting concept based on a customisedt CRAYON LED downlight solution: 122 square CRAYON LED downlights fitted with 48 W lamps in a special 625 mm size model were installed flush with the ceiling. Their warm light colour (4000 K) not only creates pleasant, uniform ambient lighting; the luminaires also have a long service life, produce colour-stable light, and are maintenance free and dimmable.

The warehouse is characterised by functional, resource-conserving architecture with many skylights that let in as much daylight as possible. Artificial lighting is deliberately only used to achieve the required level of illuminance if there is insufficient natural light. Those responsible opted to use the tried-and-tested TECTON continuous-row lighting system for ambient lighting in the warehouse. This modular continuous row system offers optimal light for industrial applications and guarantees illuminance of 300 lux in conformity with applicable standards. The system can be extended flexibly, and reflectors and emergency luminaires can be added.

CRAYON LED downlights with IP 44 protection were installed in wet locations. This 12 W downlight achieves the same lighting levels as a 50 W halogen lamp or 18 W compact fluorescent lamp. This makes it possible to replace conventional downlights by more efficient, more durable LED luminaires with little effort.

Zumtobel. The Light.

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Lighting solution
ASEAG Verkehrsbetriebe
Aachen, Germany
Owner: ASEAG Verkehrsbetriebe Aachen (DE)
Electrical installations: Frings Elektrotechnik, Alsdorf (DE)
Energy supplier saves energy

When you enter Verkehrsbetriebe’s maintenance workshop in Aachen, it's not just the buses that are fascinating - the onlooker’s eye is unerringly drawn to the very bright, pleasant lighting. The fact that this lighting also extremely energy efficient is due to the technology behind the new lighting installation.

In the two spacious workshops, 280 buses belonging to Aachen Strassenbahn- und Energieversorger AG and around 150 buses belonging to other firms are serviced and cleaned. Operating round the clock, lighting accounts for a large proportion of operating costs. The old system created a total installed load of 26,000 W and was operated 18 hours a day. Large skylights are the best way of exploiting natural light.

Thanks to new, more efficient dimmable SCUBA moisture-proof luminaires and T5 light sources, now it only takes 18,000 W to illuminate the workstations in the smaller workshop in conformity with applicable standards at 550 to 600 lux. Each individual SCUBA luminaire is connected to the LUXMATE Professional control system and an external daylight sensor, and is automatically dimmed or switched off as required. Even in cloudy weather, an installed load of 12,000 W is seldom exceeded and when the sun shines the installed load can drop as low as 5000 W! This is equivalent to a saving of more than 60%. That is even before taking into account the additional potential savings provided by presence detectors, which slowly dim and then switch off sets of 3 to 4 luminaires when there is nobody in a particular area. The spacious workshop made it possible to obtain even more impressive savings. The total installed load was reduced from 58,000 W to 30,300 W on average. When the weather is fine, installed load readings of 14,500 W are sometimes displayed on the computer station; this means that the system's payback time is only 2 years.

The emergency lighting was also upgraded to state-of-the-art standards. RESCLITE emergency luminaires with high-power LEDs are fitted on trunking. Thanks to maximum efficiency and perfect light distribution, a few luminaires are enough to provide emergency lighting in conformity with relevant standards, even when they are installed on high ceilings. And yet the powerful LED package requires a minimum of energy. The luminaire's installed load is only 5 W, in non-maintained mode it is even as low as 1.5 W.

Zumtobel. The Light.

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Lighting solution
Parker Hannifin & Co.KG
Bielefeld, Germany
Owner: Parker Hannifin GmbH & Co.KG, Bielefeld (DE)
Architect: Robert Wiehofsky, Podufal + Wiehofsky, Löhne (DE)
Electrical consultants: Fred Hölters, Elplan Ingenieurgesellschaft, Minden (DE)
Electrical installations: Schlau Elektrotechnik GmbH, Lemgo (DE)
Excellent lighting quality from a height of 18 m

Parker Hannifin GmbH’s new logistics centre in Bielefeld boasts impressive dimensions - its high-bay storage facility houses 18 m high racks that provide capacity for up to 15,000 pallets. Light must penetrate into the very lowest shelves and provide illuminance levels of 200 lux even there. This is the only way of ensuring that all item barcodes can be scanned quickly and without errors. With its outstanding lighting quality and high energy efficiency, the TECTON continuous-row lighting system impressed people right from the start. Thanks to narrow-beam reflectors and its 1x80 W light source, achieving the required illuminance level poses no problem. At the same time, TECTON’s modular system design and easy installation make it highly adaptable in the event of any subsequent extension or reconstruction of industrial buildings. Emergency lighting was built into the continuous-row lighting system to make sure that sufficient light is available even in an emergency. Three luminaires are installed as emergency luminaires in every aisle on an 11-pole track system.

TECTON luminaires with narrow-beam reflectors are also used in the 8 m high production and dispatch bay. Because the bay runs work in 3 shifts, the lighting is switched on continuously from Monday to Friday. The continuous row systems can be switched on one third or two thirds in order to reduce the lighting level as required and save energy.

Administrative and prestigious areas provide a complete contrast in lighting terms: SCONFINE Linea pendant luminaires, PANOS Q downlights and SLOTLIGHT light lines arranged in a rectangle welcome visitors into an exciting lighting ensemble. Controlled by the LUXMATE Emotion lighting management system, pre-programmed lighting scenarios can be run at the press of a button. Recessed MELLOW LIGHT IV luminaires and KAREA free-standing luminaires conjure up a lighting scene that is similar to daylight in office areas with a pleasant ratio of direct to indirect light that ensures optimal glare-free working conditions. The gentle light from SCONFINE Linea pendant luminaires produces a calm, relaxing atmosphere in the canteen. Large reflective areas provided by suspended curved elements emphasise the pleasant lighting effect achieved.

Zumtobel. The Light.

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Lighting solution
Technoalpin Bolzano
Bolzano, Italy
Owner: TechnoAlpin AG
Architect: Arch. Johannes Niederstätter VWN Architects in cooperation with Dr. Roland Baldi, Bolzano (IT)
Lighting design: Studio G GmbH, Bruneck (IT)
Electrical consultants: Studio G GmbH, Bruneck (IT)
Electrical installations: Elektro Gbitz Lorenz, Deutschnofen (IT)
At its headquarters in Bolzano, Technoalpin AG, the world's market leader in artificial snowmaking, relies on a lighting solution by Zumtobel.

Erich Gummerer, CEO TechnoAlpin AG, Bozen IT   „The lighting played a major role in the design of our new company headquarters. Zumtobel has managed to perfectly meet our requirements in terms of superior lighting quality in a variety of rooms. Zumtobel has turned out to be an indispensable partner, supplying a professional and energy-efficient lighting solution for single-person offices, the conference room and manufacturing through to components assembly."
Erich Gummerer, CEO TechnoAlpin AG, Bolzano, IT

At its headquarters in Bolzano, Technoalpin AG, the world's market leader in artificial snowmaking, relies on a lighting solution by Zumtobel. In the production areas, SCUBA moisture-proof luminaires have been installed, which at all times ensure perfect lighting conditions and reliable protection against external influences, even under the most exacting environmental conditions.

They are assisted by almost maintenance-free COPA high-bay luminaires with IP 65 protection. In the offices, ECOOS pendant luminaires provide a brilliant lighting effect that creates an exciting association with the artificial snowflakes produced by the company. The corridors are illuminated by PANOS downlights and SLOTLIGHT II light lines.

Zumtobel. The Light. 

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