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.

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.

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.

Automobile supplier Group ZF is a worldwide leader in drive and chassis technology. The company's exacting quality requirements are consistently implemented across all its sites, including the ZF Gears plant in Saarbrucken. Now fitted with a new lighting system, this site is synonymous with sustainable, reliable production processes. High-bay reflector luminaires were not up to the task of meeting today’s exacting requirements in terms of energy, lighting quality and cost. The new solution had to be flexible and energy-efficient. Zumtobel was able to satisfy its customer's needs perfectly by supplying its TECTON modular continuous-row lighting system.

The solution uses closed TECTON luminaires with T16 fluorescent lamps and dimmable electronic ballasts. These luminaires are characterised by high reliability, flexibility and long maintenance intervals. System luminaires have IP 60 protection and are also protected against dust. The spacious shop floor is uniformly lit thanks to the continuous row systems. A white vane louvre provides additional glare limitation. Lighting quality and energy efficiency are perfectly balanced and produce a beneficial lighting ambience.

MIREL recessed luminaires are used above the workstations in the office premises. T16 lamps fill the rooms with soft light. The luminaire’s special louvre minimises distracting reflections and glare, and employees can rely on optimal visual comfort 24 hours a day.

Zumtobel. The Light.

The lighting solution for the Rolls-Royce plant designed by Sir Nicholas Grimshaw & Partners at Goodwood in the South of England presented a special challenge to the architect.

The London-based firm won the competition for the design of the new Rolls-Royce plant in August 2000. Three constructional elements- a pavilion, the production building, and a paint shop – were arranged on an area of 55000 m² around a central courtyard that welcomes visitors with its impressive grandeur. The architects aimed at maximum daylight exploitation. Glass facades provide an extensive view of the main production line processes, while offering panoramic views of the landscape for the employees.

As daylight plays a crucial role in Grimshaw's architecture and philosophy in the quest for the optimum working environment, the requirements placed on artificial lighting were all the more demanding. Lighting systems and concepts had to compete with 10 000 lux and more, and at the same time support production processes of extreme technical complexity. The LIGHTTOOLS lighting channel system was used in the main reception area to illuminate the surroundings on the one hand and at the same time provides accent lighting, giving a visual definition to the entrance. In the paint shop the ZX trunking system with FZ luminaries was installed as the light has to be absolutely free of glare and disturbance in order to attain the exclusive quality of the paintwork.

Zumtobel. The Light.

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.

The district heating plant is located on the old railway station under a copper "roof body”, encompassed by a façade made of wood lamellas. The lighting solution underpins the idea of efficient handling of resources.

The longitudinal façade of the polygonal structure has been set back behind the roof edge, producing a roof projection, clad with wooden panels and CHIARO luminaires installed inside; they illuminate the asymmetrical façade and enhance the natural effect of the wood.

The building is sectioned in its interior into three functional zones: storage space for biomass, the boiler room for the wood-chip heating plant, and the combined heat and power units, for each of which an individual lighting concept was developed. In the technical workspaces, COPA A meets the requirements in terms of visual tasks, degree of protection and long maintenance intervals for industrial operations.

The glazed entrance area offers a direct view from the town side into the production bay and the connecting zones; SLOTLIGHTS fitted flush into the ceiling immerse the entrance area in pleasant, soft light with a high illuminance level. The office section has been suspended like a separate corpus into the machine room, its large-scale glass front letting in plenty of daylight. LIGHT FIELDS were installed to meet the various visual requirements such as screen-based work and sundry office jobs. They provide absolutely glare-free light and allow for free office arrangement and -sectioning. Thanks to their elegant, unobtrusive design, LIGHT FIELDS blend discreetly yet effectively into the spatial concept.
So here the lighting design dovetails in with the overall concept – the efficient handling of resources.

Zumtobel. The Light.