light for industry engineering

8/18/2019 Light for Industry Engineering

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LIGHTFORINDUSTRY

ANDENGINEERING

LIGHTFOR

INDUSTRY AND

ENGINEERING

zumtobel.com/industrie

http://zumtobel.com/industriehttp://zumtobel.com/industrie


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Light for industry and engineering


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High productivity is essentially dependent on a company’s employees. The right

lighting at the workplace helps to enhance staff members’ performance andmotivation as well as their sense of well-being – this applies to shift workers inlarge industrial bays as well as to specific manufacturing areas. Used properly,an advanced lighting solution helps to optimise conditions at workstations in manu-facturing bays, increasing motivation and preventing fatigue and, thus, industrialaccidents. Based on many years of experience and on-going research, we areaware of the effects and application options of light in industrial areas, and thisallows us to provide our customers with professional advice. Using customised

solutions and modular product ranges we ensure that perfect lighting is providedfor all rooms and areas, at any time. As energy efficiency and sustainability are theorder of the day, we are increasingly using concepts that combine daylight andartificial lighting. Our wide range of products for industry and engineering includesluminaires and intelligent control system that allow for integral solutions by a singlesupplier.

Zumtobel. The Light.


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Applications

Škoda Auto factory in Mladá Bole slav | CZ

Tryckfolket, Malmö | SE

Nike Europe, Vorst-Laakdal | BE

A. Loacker Konfekt GmbH, Heinfels | AT


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ASDA Doncaster | GB SBB Serviceanlage Oberwinterthur | CH

Hawle Armaturen GmbH, Freilassing | DE


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References


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Alpla Werke, Hard, AT / APAG Parkhaus Aachen, DE / Apipharma, Zagreb, HR /

ASDA, Doncaster, GB / ASEAG Verkehrsbetriebe Aachen, DE / AU Optronics factory, Trencin, SK / Bauarena Volketswil, CH / Bosch Rexroth Pasching, AT / Dhollandiafactory Predmier, SK / Engel Werke, St. Valentin, AT / Fernheizkraftwerk Klausen, IT /Ferrari Classiche, Maranello, IT / Fiat Kragujevac, RS / Flextronics, Althofen, AT /Freitag Taschen, Zurich, CH / Garage Delorge VW-Audi-Seat-Skoda, Sint-Truiden, BE /Güterverkehrszentrum Ingolstadt, DE / Haberkorn Ulmer, Leonding, AT / Hawle,Freilassing, DE / Hörmann Austria, Dobl, AT / Hugo Boss Shoes & Accessories ItaliaSpA, Morovalle, IT / IWT Innovative Water Technology GmbH, Lienz, AT / La Baita,

Caselle Torinese, IT / Liebherr Baumaschinen AG, Reiden, CH / Loacker KonfektGmbH, Heinfels, AT / Mondelēz Belgium Biscuits Production NV, Herentals, BE /Migros Verteilerbetrieb AG Neuendorf, CH / Nike Logistikzentrum, Laakdal, BE / ParkerHannifin, Bielefeld, DE / Rema Holzindustrie, Eben im Pongau, AT / Risse + WilkeKaltband GmbH & Co., Iserlohn, DE / Rolls-Royce Motor Cars LTD., Goodwood, GB /RSD Electronic, Naturno, IT / Rupp Käserei, Lochau, AT / Salewa Headquarters,Bolzano, IT / SBB Serviceanlage Oberwinterthur, CH / Scania Parts Logistics,Opglabbeek, BE / Schletter Leichtmetallbau GmbH, Kirchdorf, DE / Siloking, Mayer

Maschinenbaugesellschaft mbH, Tittmoning, DE / Škoda Auto factory, MladáBoleslav, CZ / Storenmaterial AG, Geroldswil, CH / Techno Alpin AG, Bolzano, IT / Technogym, Cesena, IT / Tryckfolket, Malmö, SE / Voestalpine, Krieglach, AT / Vonlanthen Holzbau AG, Schmitten, CH / ZF-Getriebe, Saarbrücken, DE


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Photo on front cover: Technogym SpA, Cesena | IT Arc hite cts: Stu dio Anto nio Cit ter io & Pa rt ner s, M il an | ITLighting solution: The production bay is characterised by a large amount of daylight.

The TECTON con tin uou s-row lig hting s yste m, cont rol led by L UXM ATE L ITE NET,adds the amount of artificial light as required. The integrated emergency lightingincreases system reliability.Other products: PERLUCE diffuser luminaire, MELLOW LIGHT recessed luminaire,PANOS downlight, RAIN moisture proof batten luminaire, ONLITE ARTSIGN escapesign luminaire


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Industry and engineering Requirements on lighting 10

Calculating the potential 12

Efficiency Introduction 14

Cutting CO2 emissions 16

Reducing energy consumption 18

Use of daylight 20

Replacing lighting systems 22

Flexibility Introduction 24

Preserving individuality 26

Changing structures 28

Coping with long distances 30

Holistic planning 32

Productivity Introduction 34

Researching the effects of light 36

Optimising visual performance 38

Supporting biological rhythms 40

Daylight as a model 42

Intelligent control 44

Reliability Introduction 46

Increasing toughness 48

Maintaining cleanliness 50

Simplifying maintenance 52

Increasing safety in emergencies 54

Lighting analysis Specimen solution for a production bay 56


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1 2Efficiency

Sustainable production technologies are becoming increasingly im-portant in almost all industries worldwide. Companies are putting inplace measures to increase resource and energy efficiency and alsoto optimise production processes, procedures and energy sources.Industrial applications have huge potential in environmental andeconomic terms and when it comes to human factors. There is of-ten external pressure as well: many industrial buildings need to bemodernised to meet applicable energy requirements.

• Reduced CO2 emissions• Lower energy costs• Less maintenance

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Requirements on lightingLight for industry and engineering

Flexibility

Increasing automation brings fast, precise workflows, and therequirements placed on activities that involve demanding crafts-manship are becoming more exacting. A space needs to cater fora variety of usage scenarios and requirements in order to take boththese aspects into account. Different ceiling heights, temperaturesand degrees of automation demand functional flexibility. Not onlythat, industrial architecture and the image that industry seeks toproject are witnessing radical change. Transparency is a sign of acompany’s strength when it comes to public relations. Cleanlinessand innovation are inner values of the future.

• Flexibility in use• Expandable as desired• Easy-to-use control

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3 4Productivity

Economic conditions demand production increases, moreefficient workflows, improved organisational structures, techno-logical progress and as few faults as possible. Productivity is along-established concept but is only now giving rise to a completerethink in many industries. Nowadays, more capital and labourare being invested in optimising productivity from the ground up.

To accompl ish this, working env ironments, work ing condit ionsand processes are being redefined.

• Fewer days lost to illness• Lower error rates• Shorter production times

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Reliability

Whereas in some industrial enterprises extreme temperatures,humidity and vibration represent major challenges, in other compa-nies extreme precision or conscientious attention to hygiene is theorder of the day. The measures to ensure maximum reliability areas different as the industrial facilities themselves. The lightingshould work at all times regardless of environmental influences,including during power cuts. Reliable emergency lighting preventsdisorientation and shows the escape routes to the open air.

• Long servi ce life guaranteed• Damage-resis tant regardless of the environment• Responsible course of action

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+ 22 %

– 86 %

+ 4 %

+ 30 %

Calculating the potentialLighting analysis tool for industry and engineering

The lighting in many i ndustr ial fac ili tie s i s not sta te-of-the-ar t.However, employees are still expected to give their best, whichunder the given circumstances can be either impossible or elsevery difficult. With innovative luminaires and a professional lightingcontrol system, however, lighting can become a factor that addsvalue. The best light for industry is:

• Light that consumes fewer resources but provideshigher 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 min-utes the potential that a new lighting system would open up for you.

The analys is resul ts are concrete numbe rs that answer pert inentquestions about energy consumption or CO

2 emissions, such as

“How much can I save?”, “Where do the savings come from?”, or“What potential does a lighting control system have?” The secondarea of the analysis refers to the flexibility of the lighting. “Wherewould it be advantageous to respond f lexibly to varying require-ments, visual activities or occupancy times?” The third level is that ofproductivity. Increases can be achieved, particularly in areas where

repetitive manual work is performed. Factors such as the wellbeingand sleep quality of employees are just as relevant as the speed atwhich tasks are performed. These are influenced by the properselection of light colour and by dynamisation of the lighting. Thefourth point to consider is the potential for reliability compared to theexisting system. You will be shown the percentage by which reliabil-ity can be increased by lighting that takes account of specific envi-ronmental conditions and carries on op erating even in emergencies.

CO2 emissions

Flexibility Productivity Reliability

The Zumtobel lig hting ana lys is too l w ill eva lua te your cur ren tlighting situation and calculate the potential for refurbishingthe lighting in the four core areas: CO

2 and cost efficiencies,

flexibility, productivity and reliability.

You can p er for m th e calc ula tio n on-l ine at t he Z umto bel web -site at any time. It only takes a couple of mi nutes to fill it in,and the results are displayed directly on-line and also outputas a comprehensive PDF document.

zumtobel.com/industriallighting

High bay lighting installed over seven years ago is often lacking inilluminance, uniformity and energy efficiency.

http://zumtobel.com/industriallightinghttp://zumtobel.com/industriallighting


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Step one: record the core data for theproject and area of application.

Step two: enter the data on theexisting lighting system and technologiesemployed.

Step three: define the zones, theirdimensions, visual tasks and ambientconditions.

The res ult : yo u w ill imm edi atel y be g ive na clear overv iew of the potential of a newlighting system. The PDF version containsall the interesting details as well.

Engel Werke, St. Valentin | ATElectrical installations: G. Klampfer Elektroanlagen GmbH, Leonding | AT

Lighting solution: The skylights allow a large amount of daylight to enter the bay. The il lum ina nce lev els of the VALUEA IP 50 h igh bay lum ina ire on TECTON tru nk-ing can be reduced as re quired, controlled by LUXMATE LITENE T.


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“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 ableto tap into potential savings in companies and help them make savings while alsobenefiting from public funding. We need capable, dependable partners by our sidein order to be able to improve customers’ competitiveness in this way. Zumtobel’sunique lighting expertise enables us to implement our ideas when it comes to effi-cient lighting. This allows our customers to cut their long-term energy costs whilealso protecting the environment.”

Efficiency

Melanie BunkeExecutive Board, EnBW EnergyWatchers GmbH | DE


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1 The introduction of Green Bui ldi ng labels and energy conservation

regulations is adding to the requirements that are part of identifyingand reducing the energy consumption of buildings. Industrial enter-prises are required to take measures designed to conserve resourcesand optimise their energy budget.

Lighting makes a vital contribution towards energy efficiency. Theproper use of lamps and ballasts in luminaires, optimised luminaireefficiency and intelligent operation are all a big step in the rightdirection. There is huge scope for lighting refurbishment projectsin industry. Many industrial plants need to be modernised to meetapplicable energy requirements. Modernisation also provides theopportunity to upgrade the quality of lighting. Beside environmentaland economic factors, ergonomics is the third pillar of sustainability.Ergonomics involves optimising production workflows and process-

es and configuring them to add value.

Companies want to assume responsibility and make customersaware they are sustainable companies. Just like using renewableenergy sources, modern lighting underscores the sustainable andinnovative nature of a company.

IWT Innovative Water Technology GmbH, Lienz | ATElectrical consultants: Elektro Green, Lienz | ATLighting solution: The modern industrial buildingis characterised bya high daylight influx. Combining this with the ZX2 flexible lightingsystem means that employees benefit from high lighting quality whilethe system saves energy at the same time.

Other products: CLARIS louvre luminaires, ONLITE emergencylighting system


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1 Efficiency Cutting CO2 emissions

Salewa Headquarters in Bolzano | IT Arc hite ctur e: C ino Zucchi Arc hite tti and Par k As soc iat i, M il an | ITElectrical consultants: Energytech, P.I. Gabriele Frasnelli, Bolzano | ITLighting solution:In addition to various standard products for industrial

applications, the IBLA office luminaire was developed for the Salewaheadquarters. Its desig n and colour match the architecture and alsomeet the strict energy require ments, with the result that the project wasawarded the KlimaHaus (ClimateHouse) certificate.Other products: MELLOW LIGHT recessed luminai re, SLOTLIGHT II lightline, TECTON Slimline continuous-row lighting system, LINARIA battenluminaire, PERLUCE recessed luminaire, LIVIANO spotlight, ONDARIAcircular luminairePhoto: Oskar Da Ritz

Key energy-balance data:CO2 saving: 330 tonnes per year

Large industrial enterprises that benefit from fixed basic electricityrates and low recurrent electricity costs have less of a battle withenergy costs but do account for a significant proportion of CO 2 emissions. Worldwide targets are being transposed into nationallaws that stipulate cuts in CO2 emissions. CO2 certificates quantifythe contribution that a firm is making towards environmental protec-tion. Companies are increasingly trying to achieve Green Buildingcertification. Labels such as LEED, BREEAM, DGNB, ÖGNI, Klima-Haus, HQE, Minergie, BCA Green Mark, CASBEE and GreenStarare used to rate the overall energy efficiency of a building. Lastbut not least, such certification also provides a marketing tool thatallows companies to position themselves as sustainable enterprises.

Refurbishing old installations provides huge scope for cutting CO 2 emissions. Many lighting systems in industrial buildings are not up

to current standards. Modernising a lighting solution can quicklysave large amounts of CO 2 and energy, and this mean that invest-ment costs are ultimately amortised more quickly. This producesnot just energy savings, but cash savings as well.

The bulk of the CO 2 emission accounted for by a luminaire is theCO 2 that is emitted while it is in service. When a luminaire is in use,efficient light sources, advanced ballasts, optimised reflectors andoptics and intelligent lighting control systems reduce actual energyconsumption. Zumtobel sets great store by sustainability during themanufacture of luminaires in order to ensure they have an optimaloverall energy balance: this starts with choosing the right materials,includes process efficiency and transport, right through to disposal.

As proof of sustai nab ili ty, an Environmenta l Product Declara tion

(EPD) is provided for every Zumtobel product. This life cycle assess-ment is in accordance with European standards for Green Buildingcertification.

• Saving energy is not simply a matter of cutting electricitycosts, it also means optimising a company’s CO2 budget

• Industrial plants can make a significant contribution towardshelping the country in which they are located achieve asuccessful CO2 balance

• CO2 certificates spell out the fact that an entrepreneur isconscious of his or her responsibilities


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VALUE A | hig h bay r efl ecto r l umi nai re PST pre sen ce d etec tor | l igh tin g managem ent sys tem

Recommended products

Risse + Wilke Kaltband GmbH & Co., Iserlohn | DELighting solution: Uniform and occasionally reduced lightinglevel using VALUEA high bay reflector luminaires dimmed bythe DIMLITE lighting management system.


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1 Efficiency Reducing energy consumption

Calculation exampleInvesting in a lighting solution using CRAFT high bay LED luminairesrather than metal halide lamps (H IE) pays for itself w ithin two to threeyears.

Power consumption per square metre per year is cut by 55% usingmodern 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%.

Energy consumption per year

Amo rti sat ion

total costs

years

€ 40,000.–

€ 80,000.–

€ 120,000.–

€ 160,000.–

€ 200,000.–

€ 240,000.–

HIE (existing) 42 × 400 W 70 kWh/m2

aCRAFT LED 35 × 280 W 32 kWh/m2aCRAFT LED 35 × 280 W 15 kWh/m2awith daylight-based and presence-based control


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Scania Parts Logistics, Opglabbeek | BE Archite cts: Hel sen & Van Com Arc hite kte n, H ass elt | BE Techn ology & ene rgy consul tan ts: Archimede s n. V.,Keerbergen | BELighting solution: The warehouse areas are not continuouslyoccupied. The lighting is therefore reduced and energysaved when they are not being used. The TECTONcontinuous-row lighting system is controlled by the

TECTON PS T prese nce dete ctor.Other products: ONLITE RESCLITE emergency luminaire

Comparing various lighting concepts, calculatingtotal costs and payback times: ec oCALC designsoftware makes it possible to check out the sus-tainability of lighting solutions and refurbishmentprojects quickly.

Saving energy starts with the right selection ofluminaires and light sources. The use of luminairesfitted with advanced electronic control gear with adimming function reduces energy consumption bysome 25%.

The rig ht l igh t a t th e r igh t ti me: i ndi vid ual on-t ime scan be defined in the LUXMATE LITENET centralbuilding calendar for the e ntire year, for example, andopen up potential savings of between 20 and 40%.

Lighting that is only switched on when it is actuallyneeded is the most frugal of all. Correctly positionedand properly functioning presence detectors help tocut energy consumption by 20 to 40%.

The most efficien t lig hting is o f course natur al da y-light, the intelligent use of which can save up to 75%of lighting energy. This free daylight influx can still beutilised even if both sunshading and glare protectionare employed. Properly coordinated control of light-ing and blinds reduces the cooling load of a buildingwhile improving lighting quality.

luminaires and light sources

presence detectors

daylight

time-based management


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Energy requirements in industry are often extremely high due tolong operating and production hours – and this includes lightingtoo: high bay lighting in par ticular requires large lumen packages.Constantly rising energy prices provide an additional incentive tosave energy.

Even the choice of light source has a huge impact on energy con-sumption. Powerful fluorescent lamps combined with high efficiencyreflectors consume significantly less energy than metal halide lamps.

Advanced LEDs are used in situations where they can play to theirstrengths – an individually manageable and controllable light sourcethat has a long service life and is largely maintenance free. Theswitch to electronic ballasts marks another milestone.

Intelligent lighting management achieves the greatest possibleenergy ef ficiency. Daylight is used as a natural light source andsupplemented with artificial light in order to maintain a constantlighting level during working hours. Increasing automation is creat-ing more and more zones and areas where people do not work at

• Extra energy consumption due to long operating hours canbe balanced out by efficient technology and lighting control

• Maximising energy savings means combining all the potentialstogether: energy-saving luminaires and light sources, custom-ized time-based management, presence detectors and theuse of free daylight

• The result is a lasting reduction in costs and CO2 over

many years.


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1 Efficiency Use of daylight

Industrial buildings are increasingly turning into architectural high-lights. Design, sustainability and quality are factors that companies

use to shape their image. Large glazed areas that delineate a build-ing are being used on an increasing scale.

Glass has two advantages, firstly it allows the use of daylight inorder to cut the need for artificial lighting and hence and secondly,glazed surfaces provide fascinating glimpses into a company.Production and employees become visible. Clear styling, brightworking environments and neatly zoned task areas improve theimage of a company. This affirmation of innovation is visually under-pinned by LED solutions. Light shines out from inside a buildingwhen it is dark outside. An architectural effect can be achievedthrough appropriate lighting design.

Industrial buildings that do not have sweeping daylight lit surfaces

can communicate with the public through façade lighting. Visiblefrom afar, façade lighting makes a building enhance a company’simage and, among other things, offers the option of raising brandawareness by using corporate identity colours and motifs. Brightlylit vertical surfaces give passers-by a sense of security.

• Sightlines into manufacturing workshops and workflowsdifferentiate and position a company

• Extensive glazed sur faces provide a reference to outwardreality but also require architecture-related lighting

• Contemporary lighting solutions enhance the image of boththe architect and the company as a brand

LUXMATE LITENET |lighting management system

LUXMATE external daylight sensor |sensor





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+ 22 % + 20 %

– 68 %

+ 10 %

Technogym SpA, Cesena | IT Arc hite ctur e: S tud io Anto nio Cit ter io & Pa rtn ers, M ila n | ITLighting solution: Ambient lighting provided by TECTON iscontrolled by LUXMATE LITENET on the basis of the generousamount of daylight entering the building. The emergency lightingis integrated, which gives a uniform appearance.Other products: PERLUCE diffuser l uminaire, MELLOW LIGHTrecessed luminaire, PANOS downlight, RAIN moisture proof batten

luminaire, ONLITE ARTSIGN escape sign luminaire

Fitness equipment is manufactured and stored in Techogym’s 11 m highproduction bay and warehouse building. The switchable T26 luminaireswere replaced over an area of more than 20,000 m2 by a TECTON T16continuous-row system with LITENET daylight-based and presence-based control. This has considerably increased the lighting system’sefficiency, and the investment will pay for itself within 2 years, thanks toreduced energy and mai ntenance costs. Over the next 20 years, thesystem will save more than 3,800 tonnes of CO2.

Other benefits: dimmability and presence-based control allow illuminancelevels to be perfectly matched to the relevant activity. As much of the

work is manual, productivity is considerably increased by the availabilityof natural light at the workstations. The li ghting system is made evenmore reliable thanks to the luminaires’ long ser vice life and the emergencylighting system.

The pote ntia l savi ngs and imp roveme nts were calcula ted usi ng the on- lin elighting analysis tool. zumtobel.com/industriallighting

CO2 emissions




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0 1 2 3 4 5 6 7 8

750 lx

The re is a h igher than average propor tion o f ageing bui ldi ngs inindustry. They consume many times the energy they actually needbecause of outdated technologies. Even if extensive renovation isnot feasible, operating costs can be cut significantly by just refur-bishing the lighting. Added value in terms of quality is reflected ina brighter environment: employees in particular benefit from thisthanks to better visual conditions, a pleasant working atmosphereand the improved quality of the entire workplace.

1 Efficiency Replacing lighting systems

• Refurbishing an out-of-date lighting solution has a positiveimpact on energy consumption, working atmosphere andoperating costs

• Modern lighting solutions reduce expenditure on maintenanceand improve lighting quality

• LED light ing and lighting control systems are an investmentin the future

Bosch Rexroth, Pasching | ATBefore the lighting was refurbished, employees complained of

excessively low illuminance levels, multiple shadows and strobing


TECTON LED | conti nuous- row lum ina ire


The changeover from T26 lamps with conventional bal lasts to T16fluorescent lamps with electronic ballasts represents real technicalprogress. LEDs take a step into the future. Switchover is especiallyeasy with TECTON because the new LED optics are 100% compa-tible with the entire product line. Old T16 and T26 modules can bereplaced by new LED luminaires without the use of any tool, andexisting trunking and wiring can therefore continue to be used.

Changing over to LEDs involves a relatively high initial investmentbut pays for itself in the long term thanks to maintenance andenergy cost savings and the improvements it brings for employees.

T16 versus LEDConventional lighting for manufacturing areas is a T16 continuous-row system. If, however, the decision is mad e to opt for a TECTON LED Wide Beam continuous-row system, it isnot just lighting quality that improves markedly: T16 luminaires require time-consumingcleaning of lamps and reflectors and replacement of all light sources once every threeyears whereas continuous-row LED systems are simply wiped down once every twoyears. Because there is no need to re place light sources, maintenance costs ar e 68%lower. Over a ten-year period, the total cost of the continuous-row LED system is actually

10% less than that of T16 lighting.

40% lower annual energy consumption

128.6 kWh/m2 T16 c onti nuous- row lum ina ire 1/80 W 76.8 kWh/m2 TECTON LED WIDE B EAM 63 W

years

Drop in illuminance


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Bosch Rexroth, Pasching | AT Arc hite ctur e: At eli er Hau ptp lat z,

Dipl.Ing. Ricardo Baumgar ten, Linz | ATLighting solution: As part of the refurbishment,a change was made to efficie nt TECTON T16lighting. Energy consumption was furtherreduced on the basis of dayl ight by LUXMATELITENET. The lighting solution was rounded offby the ONLITE emergency lighting system.

Aft er r efu rbishm ent The fle xib le TECTON tru nki ng sys tem ensure s b rig ht a mbi ent li ght ing and com for tab le wor kin g cond iti ons . A l igh tin g cont rol sys tem adj ust s th e ar tif ici al lig hting dep end ing on the amo unt of d ayl igh t th at e nter s th rou ghthe skylights. This enab les Bosch Rexroth to save up to 22,240 kWh of electricity per year. Its investment will

be amortised in less than 4 years.

38% lower annual energy consumption

22.27 kWh/m2 Existing lighting installation13.87 kWh/m2 New lighting solution using TECTON 2/49 W with LUXMATE LITENET

lighting control system and ONLITE emergency lighting system

years

€ 100.000.–

€ 200,000.–

€ 300,000.–

€ 400,000.–

€ 500,000.–

total costs

Amo rti sat ion


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“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 superiorlighting in a variety of rooms. Zumtobel has turned out to be an indispensablepartner, supplying a professional and energy-efficient lighting solution for the single-person offices, the conference room and manufacturing through to componentsassembly.”

Erich GummererCEO TechnoAlpin AG, Bolzano | IT

Flexibility


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22Industrial applications are extremely diverse and cover numerous

different areas. The requirements placed on lighting and task areafunctionality are just as varied as the areas themselves. Differentceiling heights, temperatures and working conditions underline thisdiversity, which calls for highly flexible lighting solutions that pre-serve a look that is as consistent as possible.

Driven by the demand for high output and productivity, high-speed,precision automated work processes are becoming increasinglyimportant. This makes visual tasks at manual, inspection and testworkstations more difficult, components are getting smaller, move-ments of the hand must be more accurate and are performed undercontrolled conditions.

As wel l as workf lows, architecture is also c hanging. Modernness,

innovation and sustainability must be apparent to the customer andreinforce a brand image. Transparent architecture steers people’sgaze towards production. Lighting can underscore the sustainable,innovative nature of a business.

Freitag Taschen, Zurich | CHLighting solution: Various different production areasand operations are best served by various differentlighting types, in this specific instance by the CHIAROmoisture-proof luminaire and the surface-mountedCOPA high bay luminaire.

Other products: TECTON and ZE continuous-rowsystemsPhoto: Roland Tännler


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Nike Europe, Vorst-Laakdal | BE Arc hite ctur e: S ignum NV, S int Den ijs -Wes trem | BELighting solution: Different operations demand different lightingconcepts. For example, the production bay is illuminated by the

TECTON con tin uou s-row l ightin g syste m, w hil e ot her areas areequipped with the MELLOW LIGHT recessed l uminaire or theCLARIS II pendant luminaire.Other products: PANOS downlight, LEDOS recessed floor luminaire

2 Flexibility Preserving individuality

Many companies are optimising resources and costs by introducingmore efficient processes and new work structures. The workplaceand work tasks are being impacted by greater automation. Machineinspections and quality inspections require high lighting levels, well-balanced shadow detail and – where colours are checked – verygood colour rendering. The light must also offer a certain amount offlexibility in manufacturing plants with unknown or changing pro-duction processes that are becoming increasingly more variable.Different operations impose different lighting quality requirements.Lighting that is as uniform as possible and sets of luminaires thatare controlled in groups can quickly be adjusted to meet new re-quirements and zoning. Task area-related lighting is implemented bythe control system. The second principle is that the individual needsof each employee must be met. At a time of demographic change,this is an especially interesting issue. Older people need and benefit

from relati vely highe r illuminance. The solution are concepts thatallow intervention in dimmable lighting groups or additional individualluminaires for workstations. These improve user acceptance, visualperformance and hence motivation, too.

LED product ranges offer the advantage of a variety of beam pat-terns while retaining a consistent appearance. For instance, variouslenses are used to meet different requirements in the case of the

TECTON continuous-row l ight ing system. This means it is no longernecessary to use reflectors to direct light.

• Visual requirements specific to individual operat ions areideally met by variable light focussed on the task area.

• Rising efficiency and increased automation are making newdemands on lighting

• Good light caters for people’s individual requirements,visual tasks and eyesight

CHIARO LED | moisture-proof lumina i re LUXMATE | presence detector



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Rema Holzindustrie, Eben im Pongau | ATLighting design: Elek trotechnik Kontriner, Bischofshofen | ATLighting solution: The TECTON continuous-row lighting system provides high-qualitylighting for every visual task – from inspection work through to warehousing. Theemergency lighting system incorporating an ONLITE local SB128 controller ensuressafety in an emergency.

The vis ual req uir eme nts var y w ith the opera tio n in qu est ion. I n th e wo odwor kin g i ndu str y,these range from very demanding requirements for grinding or inspecting (750 and1,000 lux respectively) through demanding work on woodworking machines (500 lux) togeneral visual tasks at the planing bench (300 lux) and the less demanding ones forautomatic drying or plywood manufacture (50 lux).

Inspecting1,000 lx

Grinding750 lx

Machining500 lx

Planing300 lx

Drying50 lx


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2 Flexibility Changing structures

Is the lighting still supposed to come on automatically at the righttime although the working hours vary? Is the plan to retrofit onearea with a daylight-based control system? Do the new assemblyoperations require a constant 750 lux instead of 500 lux? A profes-sional lighting control system can implement changes like thiswith a few clicks of a mouse. Do you want to combine or changegroups of luminaires? Add or replace groups of luminaires? Theflexible DALI addressing system in Zumtobel lighting control sys-tems allows structures to be easily changed. Organic growth isalso possible: LUXMATE covers all sizes, from just a few luminairesto over 10,000 automated output actuators. Scalability is alwayspossible, and many functions can be implemented without automa-tion components.

LUXMATE control systems incorporate many components and func-tions that have been used successfully in industrial applications formany years. The range extends from simple DALI or DSI controlsystems with adjustable lighting scenes, presence detectors anddaylight sensors to open maximum-function lighting managementsystems with interfaces to BACnet, OPC or TCP/IP.

Mondelēz Belgium Biscuits Product ion NV,Herentals | BEElectrical installations: WELEC elektro techniekn.v., Westerlo | BELighting solution: The TECTON co ntinuous-rowsystem provides uniform and efficient lighting inthe production bay. The quantity of lig ht at eachworkstation is adjusted individually via simplecontrol points.Other products: FEC louvre luminaires,central LUXMATE LITENET daylig ht-basedcontrol system

DI MLIT E | li ghting manag em ent LU XMATE LIT ENE T | li ghti ng manag eme nt system


• The flexibility requirements on lighting increase with shorterproduct cycles and increasing product diversity

• The big benefit of lighting management systems: there is noneed to change the lighting installation, the adjustment isdone by computer

• Well-trained Zumtobel service personnel take care of design,commissioning and also maintenance if required


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System grouping The fl exibil it y of a LUXMATE l ighting s olution gi ves you the opt ion of di vid -ing up or merging rooms any way you like. For instance, several single-person offices with a corridor (left) can be transformed into a team office(centre) or a conference room (right).

Improving safety Auto mati c ch ecks and fun ction test s, u nambiguo userror messages and defined emergency operatingfeatures are distinctive aspects of LUXMATE andguarantee a high level of safety.

Machine-based production

Production Warehouse

Zone Plan A Zone Plan B


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2 Flexibility Coping with long distances

As bays become inc reasingly higher, the visual tasks become moreand more diverse and above all, more demanding. Manual work,machine-based production and warehousing are all accommodatedunder one roof. This requires high illuminance levels with high-quali-ty spot lighting from considerable heights, combined with the abilityin high bays to respond rapidly and flexibly to changes in the equip-ment layout. A trunking system combined with lighting control offersmaximum lighting flexibility, allowing luminaires to be repositionedand individually adjusted at the touch of a button.

In many industrial and engineering applications, linear light sourcessuch as fluorescent lamps are the cornerstone of a rational lightingsolution, in view of the room heights involved. Continuous-row sys-tems have numerous positive features in their favour: task levels areuniformly lit, luminaires are dimmable and can also be integrated in-to emergency lighting systems thanks to their starting performance.Beyond a certain room height, however, linear light sources beginto reach their limits. Higher luminous flux levels are needed.

• The trend is for higher bays with high visual requirements• Linear solutions with fluorescent lamps and innovative high

bay LED luminaires provide impressive uniform illuminationwith dimmability and controllability.

• LED solutions boast a long service life, full output in cold en-vironments, and the capability for integration into emergencylighting systems

Hörmann Austria Ges.mbH., Dobl | AT Arc hite ctur e: Wa nnenmache r + Möl ler Gmb H, B iel efel d | DELighting solution: Adapted to the various ambient conditions, the TECTON continuous-

row lighting system illumi nates the general use areas and the warehouse, while theSCUBA and PERLUCE moisture-proof luminaires light the more sensitive areas.LUXMATE BASIC provides the control function on the bas is of daylight. Emergencylighting provided by the ONLITE central battery together with ECOSIGN and COMSIGNescape sign luminaires shows the benefits of an integral lighting solution.Other products: LIGHT FIELDS pendant lumi naire, FD downlight, MIRAL and MIRELlouvre luminaires


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15 m

9 m

8 m

4 m

12 m

Zumtobel has developed the CRAFT high bay LED luminaire as anefficient replacement for the widely used high bay reflector lumi-naires with high pressure discharge lamps. With a luminous powerup to 28,000 lumens, it combines innovative lens technology forprecise narrow-beam or square light distribution. Luminous fieldsthat do not overlap create significant extra uniformity and efficiencyfor any lighting solution. Fewer luminaires are required, significantlyreducing investment costs – irrespective of whether they are used inwarehouses, manufacturing facilities or workshops.

Thi s i s where LEDs score highly w ith a service lif e o f 50,000 hours.Over the same period, a high-intensity discharge lamp would need

to be replaced approximately four times. What is more, an LED canbe continuously dimmed and this makes it possible to fully exploitthe potential savings offered by presence and daylight-based controlsystems. The very good starting behaviour of LEDs makes themsuitable for use in integrated emergency lighting systems. LEDs arealso an ideal lighting source in cold ambient temperatures. The lightoutput of fluorescent lamps is adversely affected by below-zerotemperatures whereas the luminous flux of LEDs remains constant.


TECTON LED | conti nuous- row lum ina ire

TECTON LED Wide Beam

• In production areas, emphasis is placedon uniform illumination of surfaces.

• Machines and manufacturing areas can

be planned and used independently ofthe lighting solution. This allows flexibleproduction concepts without any needfor action as far as luminaire positioningis concerned.

TECTON LED Narrow Beam

• Illuminance levels have been optimisedfor medium and hig h racking; the focusis on aisle areas.

• A specially designed and installed solu-tion will provide uniform illumination ofaisle areas and shelf surfaces.

CRAFT | high bay LED luminaire

CRAFT Narrow Beam

• Light distribution and illuminance levelsare optimised for the efficient and uni-form lighting of long and high shelf rows.

• As a distinctly narrow-beam solution,it uses the spacing between one LEDluminaire and the next to full ef fect.

The spa cin g can be u p to 15 m wheninstalled at a height of 15 m.

CRAFT Wide Beam

• Perfect beam pattern for high bay useswith production areas where peoplehave to work reliably and with concen-

tration.• The light from the LED hi gh bay luminairehas well-controlled glare and is uniquelyefficient and uniform. This is made pos-sible by a lighting cone that is shapedlike a pyramid with a square base.

200 lx on shelf surfaces,100 lx on the floor

300 lx on the floor110 lx on shelf surfaces,160 lx on the floor

1,200 lx on the floor

7.5 m

1.5 m

3.5 m


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2 Flexibility Holistic planning

Schletter Leichtmetallbau GmbH, Kirchdorf | DEElectrical consultants: Elektro Seidinger GmbH,Bachmehring | DELighting solution: Transparency from the of fice to theproduction bay – the TECTON continuous-row l uminaireand its balanced br ightness level put the idea i nto animpressive solution.


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Industrial applications are strikingly diverse; they range frommanufacturing workshops and warehouses, underground carparks and offices through to test and inspection workstations.

The more d isparate the requirements, the more important it isto obtain a lighting solution from a single source. Zumtobel cansupply the right lighting components for every location andevery area of activity – sometimes from within a single lumi-naire product line – in order to solve different visual tasks whilemaintaining a consistent design. Zumtobel lighting solutionsprovide flexibility to adapt to on-going changes by groupingluminaires together and the ability to dim them, thus adjustinglighting levels. Systems that are controlled by a single lightingcontrol system reap the benefit of integrated control and nu-merous operating and maintenance synergies.

Integrated lighting concepts for industrial buildings involveconsidering architecture and usage circumstances separately.Zumtobel’s extensive product portfolio includes lighting solu-tions for every application area: from lighting for offices andconference rooms through to underground car parks and fromwide-area lighting using downlights through to façade lighting.

• Different app lications that make different demands on lightingare mixed up in industrial buildings

• Taking into account circulation routes, workflows and areas ofactivity throughout an entire building makes orientation easier

• A lighting solut ion and lighting control system that t ake across-building approach use light in a targeted manner, thusreducing expenditure on energy

PANOS INFINITY | LED downlight


LIGHT FIELDS LED | recessed luminaire


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Productivity Introduction

“Production work often involves shift work. Nowadays it is taken for granted thatshift work has a negative impact on the risk of accidents and sleep quality. Roomlighting can have a positive effect, especially in times when work-related stress isincreasing due to an arrhythmic lifestyle. A “productive” lighting solution meets bothvisual and biological needs. Such lighting solutions often include a lighting controlsystem that varies the intensity of light and light colour based on specific workinghours and shift models.”

Markus CanazeiBartenbach LichtLabor GmbH, Aldrans | AT


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3In today’s society, more and more information is being processed

even more quickly. Human productivity is predicated on absorbingcontent quickly. Striving for extra output leads to continuously moreefficient workflows, changing organisational structures and alteredunderlying conditions. Light makes it possible to cope with visualtasks effortlessly without making mistakes. Poor visual conditionshamper work, make people feel ill at ease, reduce productivity andlead to mistakes and accidents. Conversely, good visual conditionscreate an atmosphere in which workers feel at ease, which boostsmotivation, aids concentration and makes them more productive.Improvements in lighting quality result in demonstrable reductionsin error-proneness.

Employees have to cope with fatigue in situations where shifts areworked from early in the morning until late at night or in the case of

round-the-clock working. This strain can be minimised by a lightingsolution that delivers the right amount of light, good direction of lightand light colour that are optimum at the appropriate time.

RSD-electronic GmbH, Naturns | IT Arc hite cts: Dr. Walt er Dietl, Sch lan der s | ITElectrical consultants: Studio ingegneriDr. Fleischmann & Dr. Janser, Laces | ITLighting solution: Light Fields and CAREENArecessed LED luminaires ensure the necessary

lighting quality and high illuminance levels forprecision work.Other products: PANOS INFINITY LED downl ights,SLOTLIGHT II light line, ELEEA pend ant luminaire,SCUBA moisture-proof luminaire, RESCLITE LEDemergency luminaire, ARTSIGN escape signluminaire with central monitoring


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21:00 22:00 23:00 24:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00

3 Productivity Researching the effects of light

What influence does dynamic light ing have on the well-beingof employees who work shif ts? To answer this question,Zumtobel relies on scientific research, either direct ly in thefield or in the laboratory. The study results show that dynamiclight has a demonstrably positive effect on productivity byreducing physiological strain and improving performance. Asa less costly alternative, high-frequency dynamic lighting canincrease activity and reduce the stress factor.

A detai led ana lys is of n ight-time acti vi ty levels shows t hat sta tic amb ien t l igh tin g duri ngworking hours (blue line) results in significantly poorer sleep quality. Dynamic lighting(red and green lines) shows significantly calmer night-time activity levels.

Effects of dynamic lighting scenariosMany people who work early morning shifts in industry complainabout poor sleep and are unable to work at maximum productivity,as both performance and regeneration are demanded at the

“wrong” time. Zumtobel initiated a field research project at theFlextronics electronics company to demonstrate that lightingsolutions with dynamically controlled illuminance levels and colourtemperatures successfully counter this phenomenon and thatsignificant productivity increases are possible. The results:

• Dynamic room lighting conditions significantly improve sleepquality and have a positive impact on the wellbeing of workersduring and after shift work.

• The average time for performing the work tasks fell significantlyduring the winter months compared to the standard time.

time

Effects of short-frequency dynamic lighting To test the new research and to f ind a less costly alternati ve to bio -logical light direction, Zumtobel, in conjunction with the BartenachLighting Laboratory, gave a number of test subjects the task of

constructing simple and complicated pre-set shapes with Legobricks. Unlike previous studies, the control system did not follow a24-hour rhythm but used shorter stimulation frequencies, orientedto the breathing and blood pressure rhythms of human biology.

The results showed that:

• Breathing light with illuminance changes from 500 to 680 lux every10 seconds is less tiring and more interesting and stimulating. Thetest subjects were more active in the early evening and slept moresoundly at night.

• Light increased at an hourly frequency from 500 to 2,000 lux in asaw-tooth pattern reduced the physiological reactions to stress.


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Flextronics, Althofen | ATLighting solution: TECTON continuous-row l ighting system,LUXMATE EMOTION lighting management system


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3 Productivity Optimising visual performance

Recommended productsLUXMATE EMOTION |lighting management system

TECTON LED | co ntinuous- row lum ina ire

Ferrari S.p.A., Maranello | IT Arc hite cts: Pro spa zio , Mode na | ITLighting design: Arch. Francesca Nasi, Carpi | ITLighting solution: High illuminance levels reduceerror rates and reveal details more clearly. At Ferraria TECTON continuous-row LED system provides ahigh level of lighting at 1,000 lux with good colourrendering. The light is dimmed on the basis ofdaylight by a LUXMATE DAYLIGHT lighting controlsystem.


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140 %

130 %

120 %

110 %

100 %

100 200 300 400 500 600

200 300 400 500 60 0 700 800 900

114

44 43 3725 21 13 15 9 11

100

Light has a major impact on the performance of employees andon the frequency of errors and accidents in the workplace. Makingit possible to cope effortlessly with visual tasks is therefore the firstconsideration when it comes to lighting design. An adequate light-ing level is required in order to be able to concentrate on work andremain motivated. In addition, high illuminance has a positive effecton commitment, error rates and the risk of accidents. A pleasantroom atmosphere is obtained through a combination of direct andindirect light, vertical illuminance or a zonal lighting solution.

Visual comfor t i s obtained as a resu lt of the human eye hav ing toaccommodate less often when switching from viewing the work taskto viewing the room. Other consequences: employees feel at ease,are motivated and identify with their workplace.

• Lighting design concentrates on accomplishing visual taskswithout making mistakes

• Smaller details are more visible with high illuminance levels,and the number of accidents decreases

• Pleasant dist ribution of luminance levels in a space, and abalanced mix of directional and diffuse light enhance visualcomfort

Performance

A h igh er ill uminanc e leve l i ncrea ses per for manceSource: Ilmenau Technical University: “Nutzen e iner besseren Beleuchtung”,(Benefits of improved lighting), Abschlussbericht (Final Report), Gall, Völker.

Cutting to size

Drilling

Sawing

Stripping insulation

Punching

Number of industrial accidents

Higher illuminance levels reduce the number of industrial accidentsSource: Ilmenau Technical University: “Nut zen einer besseren Beleuchtung”,(Benefits of improved lighting), Abschlussbericht (Final Report), Gall, Völker.

lx

lx1,000 1,100

140%

130%

120%

110%

100%


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3 Productivity

Supporting biological rhythms

Ferag AG, Hinwil | CHLighting solution: With a large daylight influx, work on conveyor andprocessing systems takes far less effort – like working in the open air.If there is a lack of dayli ght, the TECTON continuous-row lightingsystem steps in to replace it with perfectly uniform lighting. Thelighting is controlled by the DIMLITE multifuntional 2-channel lightingcontrol system.


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TEC TON LED 6,500 K |continuous-row luminaire


• Light affects an individual’s natural circadian rhythms andprevents fatigue

• Light with short-wave blue spectral components stimulates,while warm white light has a relaxing effect

• Light whose colour temperature changes dynamicallyhas a positive influence on people’s health

Besides its visual and emotional effects, the biological effect oflight is also important. Colour temperatures affect mood. The warmwhite spectrum has a relaxing effect and increases an individual’swellbeing. Cool white light, on the other hand, is stimulating. Themotors for this are the blue short-wave light components. Biologi-cally perfect lighting is variable and makes full use of the avail-able possibilities at any given time. Judiciously used illuminancelevels and light colours synchronise human circadian rhythmson a long-term basis, and this has a positive effect on health.

Thi s i s par ticula rly r elevant i n the case of n ight shi ft workingwhen employees’ normal day-night rhythms can be disrupted byatypical working hours. Shift work and its associated night-timelighting have a tiring effect on people. Nevertheless, people canbe helped by the provision of biologically effective light, depen-ding on the nature and duration of the shift work. Various dynamiclight variation concepts pursue different objectives: a change incolour temperature can stimulate or relax workers in the shortterm. It is also possible to exert a long-term positive effect onsleep patterns and health. Biological lighting also has the abilityto synchronise or shift the natural human circadian rhythm in thelong term. With alternating day and night shifts, synchronisationis achieved by using colour temperatures that follow the naturalchanges in daylight. However, in the case of permanent night shiftworking it is better to adapt the rhythm. This is done by using ahigh proportion of blue at high illuminance levels at the beginning.

Flextronics, Althofen | ATLighting solution: As part of the research project described

on page 36, a TECTON continuous-row li ghting system wasnstalled, controlled by a LUXMATE EMOTION lighting man-agement system, in order to prove the effects of d ynamicighting on shift workers.


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3 Productivity

Daylight as a model

Large amounts of daylight are available in a steadily increasingnumber of industrial bays. The large glass façades have a symbolicsignificance as well as a lighting aspect. Allowing outsiders anuntrammelled view into a building symbolises a high degree oftransparency and emphasises a high awareness of quality.

Employees in the bays find the natural daylight particularly pleasant. The ir wel lbeing and potential for stimulation is a second impor tantargument, after energy efficiency, for using daylight as intensivelyas possible. The colour temperature of sunlight varies – with the ex-ception of the very early morning and late evening hours – between5,000 and 6,000 K. Artificial cool white light emulates this and soavoids mixed lighting situations with different colour temperaturesfrom daylight and artificial light. Another benefit: cool white is per-ceived subjectively as being brighter and is regarded by employeesin a positive way.

• Natural daylight has very special qualities and everyoneperceives it as being pleasant.

• Cool white lighting in an interior enhances the naturaleffect of light and avoids mixed-lighting situations.

• Cool white LED luminaires combine visual comfort withalmost unparalleled efficiency.


CRAFT 6,500 K | h igh bay LED luminaire SCUBA 6,500 K | moisture-proof diffuser luminaire


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Alp la Werke , Ha rd | ATLighting solution: The plastics manufacturer has been usingluminaires with cool white 6,500 K lamps for many years,achieving an almost seamless transition between outdoorsand the production bay. This concept was impl emented in thelatest lighting refurbishment with the 6,500 K TECTON continuous-row LED system for greater efficiency and higher lighting quality.


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3 Productivity

Intelligent control

Mondelēz Belgium Biscuits Production NV, Herentals | BELighting solution: The TECTON continuous-row lighting systemmeets the high requirements in the prod uction and warehousingareas on reliability at various ambient temperatures while ensuringfood hygiene. The central LUXMATE LITENET control system de-creases the lighting on the basi s of daylight and the presence ofstaff, thereby saving energy and prolonging the service life of thelighting solution.Other products: FEC louvre luminaires for offices


TECTON LED | co ntinuous- row lum ina ireLUXMATE LITENET timeline editor |lighting management system


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06:0002:00 04:00 12:00 18:0016:0014:0010:0008:00 24:0020:00 22:00

06:0002:00 04:00 12:00 18:0016:0014:0010:0008:00 24:0020:00 22:00

8:00:00 8:00:40 8:00:80 8:01:20 8:01:60 8:02:00

For more activity and less fatigue:breathing light with illuminancechanges from 500 to 680 luxevery 10 seconds.

If employees often have to changebetween day and night shifts: highluminous intensity at the start ofworking hours stabilises the circa-dian rhythm.

For permanent night-shiftworking: high illuminance levels(or high colour temper atures) at

the beginning of each shift helppeople to adjust to the workinghours.

To promote an ind iv idual ’s well being and productivit y i n i ndustr ia lplants effectively, light is needed that meets human requirements asunobtrusively as possible. The key to this is varying the quantity andcolour of the light. Employees working in shifts frequency sufferfrom problems with health and poor quality of sleep. Lighting playsa central role here, and precisely when and how the lighting is usedis of great importance.

• Light for people that promotes both wellbeing and motivationcan only really be achieved by using a lighting control system

• Timelines are used to implement a wide variety of individualproject requirements

• Graphic editors are simple to use and are an important toolin utilising the advantages of dynamic lighting in in everydaysituations

time

time

time

Concept for biologically effective light

A lighting contro l system combines the var ious components o f alighting solution and puts the requirements on the biological effectsof light into practice. In addition to standard automation featuressuch as daylight-based or presence-based control, a dynamiclighting system can also offer individual timer settings. The graphiceditor makes it easy for the user to define the illuminance level andlight colour at any time of day or night. Zumtobel systems includepredefined timelines as an aid that can be adapted very easily tolocal conditions.

1,000 lx

750 lx

250 lx

500 lx

0 l x

1,000 lx

750 lx

250 lx500 lx

0 l x

1,000 lx

750 lx

250 lx

500 lx

0 l x


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Reliability

Heribert CzarnetzkiMaster Electrician Otto Fuchs KG, Meinerzhagen | DE

“In industry, the requirements in terms of lighting for workstations haveincreased over the past years. Optimal lighting today is characterised bycustomised innovative lighting technology integrating the amount of daylightavailable. The proper arrangement of luminaires, as well as the efficiencyand cost-effectiveness of luminaires and lamps play an essential role in thisrespect. The choice of luminaires depends on ambient conditions – difficultat times –, such as room height, ambient temperature and dirt load. In orderto provide for easy cleaning of the luminaires and smooth replacement oflamps, we attach great importance to good accessibility and easy handling.”

Heribert CzarnetzkiMaster Electrician Otto Fuchs KG, Meinerzhagen | DE


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4Working hours can be long in many industrial enterprises, often ex-

tending over two or three shifts. This entails long periods of opera-tion, including for lighting. The requirements for a long ser vice lifeare therefore highly relevant in industry, where the lighting shouldnot fail or be merely satisfactory in operation after five years. An LEDsolution is therefore advisable on the grounds of the higher expectedservice life alone. The dimmability offered as standard with LED lumi-naires and its associated reduced periods of operation also has theeffect of extending their service life.

Ambient and operating cond itions play an important role in theselection of the best possible lighting solution. Very high or very lowtemperatures have a significantly negative effect on the efficiency ofvarious light sources. Humidity, dirt or chemical particles also call fora correspondingly resistant luminaire housing. A sealed luminaire

with the appropriate IP rating ensures that no foreign bodies enterthe luminaire. Lighting is necessary not just to ensure industrial safetyand reliability; it is also responsible for showing employees the routeto safety in emergencies.

Mondelēz Belgium Biscuits Production NV, Herentals | BELighting solution: The TECTON continuous-row lighting systemmeets the high requirements in the production and warehous-ing areas on reliability at various ambient temperatures whileensuring food hygiene. The central LUXMATE LITENET controlsystem decreases the lighting on the bas is of daylight and the

presence of workers, thereby saving energy and prolonging theservice life of the lighting solution.Other products: FEC louvre luminaires for offices


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4 Reliability Increasing toughness

Dark areas create a feeling of insecurity; employees and visitors feelsafer in a room that is consistently bright. Ideally, the entire room canbe taken in at a glance. This is ensured by bright rooms that havebright vertical sur faces; glare and excessively high or low illuminancelevels can be distracting.

Moisture-proof luminaires afford long-term protection and goodefficiency in harsh environments. They are extremely resistant to dust,moisture, chemicals, mechanical stresses and extreme ambienttemperatures. Zumtobel uses various materials and degrees of pro-tection to meet specific challenges.

When planning a project, any expected environmental influences andthe luminaires suitable for the application must be clarified exactly.

Explosive atmospheres in industry are an often underestimatedhazard. Mixtures of gas and air or dust can lead to an explosion andcause immense injury to people and damage to equipment. Gas ex-plosions are an issue in the chemical industr y in particular. Sawdust,fodder, food, plastic and carbon dust can cause dust explosions.

As a potent ial ign ition source, lumina ires fo r haza rdous locat ionsmust not cause ignition in an explosive atmosphere – Zumtobel suppliesluminaires that are suitable for Zones 1/21 and 2/22 in accordancewith the ATEX directive.

• Bright environments with bright vertical surfaces make itpossible to take in an entire room at a glance, thus creatinga feeling of greater safety

• Environmental influences dictate the protection rating ofa luminaire

• Explosion-proof luminaires ensure safety in industriallocations where harmful dust or gases are liable to occur

TUBILU X L ED | tubula r L ED l umi nai re


KXB 2 LED | explosion-proof luminaire

Scania Parts Logistics, Opglabbeek | BE Arc hite cts: Hel sen & Van Co m A rch itekten, H ass elt | B E Techn ology & energy con sul tan ts: A rch ime des n. V., Keer ber gen | BELighting solution: The TECTON continuous-row lighting system iscontrolled by TECTON PST sensor s on the basis of the presence ofusers. RESCLITE luminaire is incorporated in the system.


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APAG Park hau s Aa che n | DEOperator: Energieversorgungs- und Verkehrsgesellschaft Aachen | DELighting solution: There are no dark areas in this multi-storey car park.

The dim mab le SCU BA L ED IP 65 moi stur e-p roo f l umi nai re i s contr oll edon the basis of the presence of visitors and consequently offers them auniform and comfortable lighting situation at any time of day.


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Pasticceria La Baita srl, Caselle Torinese | ITLighting solution: The high requirements on cleanliness and purityare reliably met by the TECTON continuous-row lighting system.

The ONL ITE RE SCLI TE eme rge ncy lum ina ire is incorpor ated inthe system.

4 Reliability Maintaining cleanliness

SCUBA LED |moisture-proof diffuser luminaire


CLEAN LED | clean-room luminaire


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A. Loacker Kon fek t Gm bH, Hei nfe ls | AT Arc hite ctur e: L ien z a rch itect p ar tner shi p | ATLighting solution: The SCUBA moisture-proof luminaire, installed on

TECTON tru nki ng, wit hst ands th e dema ndi ng a mbi ent con dit ions.Other products: MELLOW LIGHT recessed luminaire

The many arguments in favour of bri ght, c lea n l igh ting a re matchedby Zumtobel’s versatile range of luminaires that offer as few surfac-es as possible on which dirt can settle. Cleaning is more efficient,first impressions are great and product quality improves. Besidesdegrees of protection and associated resistance to impact bychemicals, dust or extreme temperatures, Zumtobel relies onsmooth surfaces and no loose parts.

Zumtobel relies on good to very good colour rendering in order toensure that products or ingredients in the food processing industrycan be assessed correctly. Relevant guidelines laid down, for in-stance, by International Food Standards (IFS) and the British RetailConsortium (BRC) set minimum standards for food production andflag up areas where there is room for improvement when guidelinesare revised on an annual basis. All versions of the SCUBA moisture-proof luminaire basically meet the requirements in order to obtain

system certification. It is ensured that the luminaire is shatter-proof,contains no glass, has an enclosed light source and, hence, nosplinters can get into the food product if the lamp breaks. This pro-vides proof of food-safe design. The Hazard Analysis and CriticalControl Points (HACCP) method is used to determine risks to thesafety of food and actively reduce them. Choosing the right lightingin terms of safety, protection, maintenance and efficiency helps thefood processing industry achieve these goals.

Production under controlled conditions opens up the possibil-ity of new, more effective and more accurate methods. Variousorganisations and standards such as Good Manufacturing Practice(GMP), the Food and Drug Administration (FDA) and the GermanMedicinal Product Law set out specific recommendations for

equipping clean-rooms. Among other items, this includes lumi-naires with IP 65 protection that are suitable for use in roomswith positive or negative pressures. Other specifications relateto ability to withstand cleaning agents and disinfectants andlow particle emission behaviour. Installation flush with the ceil-ing or surface mounting may also be required depending on theconstruction of the ceiling and the particular application area.

• Cleanliness and hygiene are promoted by bright,low-maintenance, easy-to-clean lighting systems

• Cleanliness during manufacture is becoming more importantas increasing demands are placed on product quality

• Difficult visual tasks such as precision inspections or wiringare made easier by good lighting and a clean environment


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4 Reliability Simplifying maintenance

Freitag Bags, Zurich | CHLighting solution: Various production areas and operations are best served byvarious lighting types, in this specific instance by the CHIARO moisture-proofluminaire and the surface-mounted COPA high bay luminaire.Other products: TECTON and ZE continuous-row systemsPhoto: Roland Tännler


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Zumtobel’s product portfolio features particularly low-maintenanceunits that have a long service life, and it meets industrial requirements:many luminaires in high bays are difficult to access; maintenance andfrequent relamping are therefore very expensive. Reducing the needfor maintenance also means less frequent disruption of manufacturingprocesses. With an average service life of 50,000 hours and a guaran-teed end-of-life luminous flux in excess of 70%, LED luminaires are vir-tually maintenance free for long periods of time. Even cleaning is par-ticularly easy thanks to the compact design sizes that are achievableby combining LED light sources, battens and optics. Another benefit ofLEDs is the fact that they limit the visible light spectrum. LED light isfree from ultraviolet and infrared radiation and does not harm even plas-tics that fade easily.

The temptation to mode rni se old fluoresc ent lamps by fi tt ing LED tubu-lar lamps is huge, but caution is required. Many LED retrofits are notcompatible with the technical lighting and electrical requirements of aluminaire. As the LED retrofit and luminaire were not tested as a singleunit, confirmations for marks of conformity have to be applied for againafter upgrading, and the firm which carried out conversion will be heldliable in the event of any damage or claim. The reflector and optic in aZumtobel luminaire are precisely matched to the fluorescent lamp, andupgrading to a LED tubular lamp results in a markedly different beampattern. The specified luminous intensity curve can no longer be guar-anteed and the photometric calculations used to determine illuminanceand glare are no longer valid. The primary attraction of retrofit solu-

tions is the fact that they consume less electricity than fluorescentlamps of the same length. This initial attraction soon fades, however,when one realises that LED retrofits emit roughly 50% less light thanmost LED and fluorescent lamps.

• Maintenance is a crucial factor in high bays and in situationswhere luminaires are hard to access

• State-of-the-art LED solut ions have the advantage of longservice lives

• In contrast , LED retrofit lamps often involve excessivecompromises when it comes to lighting quality, technicalsafety and energy efficiency

ONLITE RESCLITE | emergency luminaire


METRUM | continuous-row system


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4 Reliability

Increasing safety in emergencies

Environmental conditions can sometimes be extremely harsh in in-dustry. Zumtobel offers escape sign and emergency luminaires withIP 42, IP 54 and IP 65 protection to make sure that the esca peroutes are reliably illuminated in an emergency despite harsh con-ditions – these products are well protected against dust and water.High bays pose additional challenges for emergency luminaires.RESCLITE High Ceilings escape route luminaires and anti-panicspots guarantee reliable orientation even from a height of 7 to20 metres. The spacing between LED luminaires can be up to21 metres. The combination of IP 65 and a central supply makesthe luminaires practically maintenance-free.

• 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

Sturdy low-cost LED luminaires like CROSSIGN are characterisedby high toughness, ease of installation and perfect lighting technolo-gy. Two ERI spots on the underside give the escape sign luminairesthe qualities of an emergency luminaire. This means that thanks tothe latest LED technology, a saving is made not only in electricitybut also in the number of luminaires.

The logi cal rep ly to the continuous reduction in power of LED emer-gency and escape sign luminaires on the supply side is the first

TÜV-ce rt if ied centra l bat ter y. eBox meets all the requireme nts forcentral and group battery systems under EN 50171 and can beused in both very small and in major projects. Its high reliabilitystarts with easy installation and wizard-led commissioning, contin-ues with an easy-to-use web browser user interface and culminatesin a permanent display of the expected battery life. If SUB stationsare used, the fire load on the building is reduced by 70%.

CROSSIGN 160/110 |scape sign luminaires


ONLITE RESCLITE for gre ater heights |LED emergency luminaires

ONLITE CENTRAL eBox | emergency light-ing supply system


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55

Rema Holzindustrie, Eben im Pongau | ATLighting design: Elek trotechnik Kontriner, Bischofshofen | ATLighting solution: The ONLITE ECOSIGN escape sign luminaireis controlled by the ON LITE local SB128 controller.


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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

–71 %

–13 %

Specimen solution for a production bay Lighting analysis

Electronic components are produced, packed and stored in anarea of 1,200 square metres in this specimen bay. The height of thespace is six metres, and daylight enters along a window frontageon one side and through skylights. The bay was lit by HID reflectorluminaires prior to refurbishment. The comparison with a lightingsolution using VALUEA T16 high bay reflector luminaires and anoth-er LED lighting solution with CRAFT and LUXMATE LITENET clearlyshows the potential of an innovate lighting solution.

HID high bay luminaire (existing)with RAB reflector

T16 high bay luminaire CRAFT 330 WB with LUXEMATELITENET lighting control system

Light source HID T16 LED

Installed load 250 W 216 W 140 W

Number of luminaires 90 off 99 off 110 off

Luminous flux 19,000 lm 17,800 lm 12,600 lm

Luminaire efficiency 76 lm/W 82 lm/W 90 lm/W, 4,000 K, Ra 80

Benefits • Low total installed load • Low installed load• Low maintenance• Dimmable• Daylight integration

Disadvantages • High energy consumption• High maintenance• Low efficiency

Development of total costs over service life

€ 700,000.–€ 800,000.–

€ 500,000.–

€ 300,000.–

€ 100,000.–

years

€ 200,000.–

€ 400,000.–

€ 600,000.– Amo rti sat ion

HID high bay luminaire

T16 h igh bay lum ina ire

CRAFT with LUXMATE LITENET

T16 h igh ba yluminaire

CRAFT with LUXM ATELITENET

HID high bayluminaire

CO 2-emissions over service life (20 years)

1,200 t

1,000 t

800 t

600 t

400 t

200 t0


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57

+ 45 %

– 71 %

+ 8 %

+ 20 %

– 13 %

+ 10 % + 10 %


CO2-emissions


1. CO2 and cost efficiencies

The existing lighting so lut ion consumes 93.5 kWh o f power persquare metre and year; the CRAFT LED lighting solution, however,which is controlled by LUXMATE LITENET, consumes only26.88 kWh. This corresponds to a reduction by 71 percent, withthe lighting control system accounting for some 48 percent. Thealternative solution using T16 high bay luminaires reduces energyconsumption by 13 percent.

2. Flexibility The ill uminance level is 750 lux throughout the bay, des ignedto meet the very demanding visual tasks in the production area.

The abi li ty to reduce the light ing level to 300 l ux at the packingstation and to 150 lux in the finished goods warehouse reducesunnecessary energy consumption and provides flexibility.

3. Productivity The lower the ill uminance level of amb ien t l igh ting, the higher itsfactor for additional motivation. By increasing the lighting level by12 percent in the warehouse, by 10 percent at the packing stationand by 5 percent in the production area, productivity is increasedby an average 8 percent.

4. Reliability The fact that the lum inous flux of a CRAFT lum ina ire doe s notdecrease even in case of high temperatures below the bay’s ceilingmakes the lighting all the more reliable. Another important aspectis the high bay LED luminaire‘s low failure rate, which results in lessfrequent downtimes and lower maintenance costs.



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Order no. 04 570016-EN 06/13 © Zumtobel Lighting Gmb H Techn ica l d ata was cor rec t at time of goi ng to p res s.We reserve the right to make technical changes withoutnotice. Please contact your local sales office for furtherinformation. For the sake of the environment: Luxo Light ischlorine-free paper from sustainably managed forestsand certified sources. pefc.org PEFC/06-38-214

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• Offices and Communication • Education and Science • Presentation and Retail

• Hotel and Wellness • Art and Culture • Health and Care • Industry and Engineering • Façades and Architecture

Zumtobel is the internationally leading supplier of integral lighting solutions forprofessional interior and exterior lighting applications.

We provide unique customer benefits by integrating technology, design,emotion and energy efficiency. Under the Humanergy Balance concept, wecombine the best possible ergonomic lighting quality for an individual’s well-

being with the responsible use of energy resources. The company’s ownsales organisations in twenty countries, as well as commercial agencies in fiftyother countries, form an international network of experts and design partnersproviding professional lighting consulting, design assistance and comprehen-sive services.

Lighting and sustainabilityIn line with our corporate philosophy “We want to use light to create worlds ofexperience, make work easier and improve communications and safety while

remain ing ful ly aware of our respons ibi li ty to the env ironme nt”, Zumtobel offersenergy-efficient high-quality products, while at the same time making sure thatour production processes based on the considerate use of resources areenvironmentally compatible.zumtobel.com/sustainability

Top quality – with a five-year guarantee. As a g lob all y l ead ing lum ina ire man ufactur er,Zumtobel provides a f ive year manufacturer'sguarantee on all Zumtobel branded productssubject to registration within 90 days from theinvoice date and in accordance wi th the termsof guarantee at zumtobel.com/guarantee.

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United KingdomZumtobel Lighting Ltd.Chiltern Park Chiltern Hill, Chalfont St. PeterBuckinghamshire SL9 9FG

T + 44/ (0)1753 482 650F +4 4/(0)1753 480 [email protected] zumtobel.co.uk

USA and CanadaZumtobel Lighting Inc.3300 Route 9WHighland, NY 12528

T +1/(0 )84 5/691 6262F +1/(0)845/691 [email protected]

Australia and New ZealandZumtobel Lighting Pty Ltd333 Pacific HighwayNorth Sydney, NSW 2060

T + 61/(2) 8913 500 0F +61/(2)8913 [email protected]

ChinaZumtobel Lighting ChinaShanghai officeRoom 101,No 192 YIHONG Technology Park

Tianl in Road, X uhui Distr ictShanghai City, 200233, P.R. China

T + 86/ (21) 6 375 6262F +86/(21) 6375 [email protected]

Hong KongZumtobel Lighting Hong KongUnit 4319-20, Level 43,

Tower 1, Me tro pla za,223 Hing Fong Road,Kwai Fong, N.T.

T + 852 /(0) 2503 0466F +852/(0)2503 [email protected]

IndiaZumtobel Lighting GmbH

Vip ul Trade Ce ntre , 406, 4th Flo orSohna Road, Sector 48,Gurgaon 122002, Haryana, India

T +91/124 4206885 [email protected]

SingaporeZumtobel Lighting Singapore158 Kallang Way # 06-01/02Singapore 349245

T + 65 684 4 5800

Romania Zumtobel Lighting Romania SRLRadu Greceanu Street, no. 2,Ground Floor, sector 1012233 Bucharest

T + 40 731 32 [email protected] zumtobel.com

Hungary Zumtobel Lighting Kft

Váci út 4 91134 Budap est

T + 36/ (1) 35 00 828

F +36/(1) 35 00 [email protected] zumtobel.hu

Croatia, Bosnia andHerzegovina Zumtobel Licht d.o.o.Radnička cesta 80 – Zagrebtower10000 Zagreb

T + 385/(1) 64 04 080F +3 85/(1) 64 04 [email protected] [email protected]

Serbia Zumtobel Licht d.o.o.Karadjordjeva 2-4Beton Hala11000 Belgrade

T + 381/(0)11 6 5 57 657F +3 81/(0)11 65 57 [email protected]

Czech RepublicZumtobel Lighting s.r.o.Jankovcova 2Praha 7170 00 Praha

T + 420/(2) 66 782 200F +420/(2) 66 782 [email protected]

Slovak RepublicZumtobel Lighting s.r.o

Vlčie Hrd lo 1,824 12 Br [email protected] zumtobel.sk

PolandZumtobel Licht GmbH Sp.z.o.o.Platinium IIIul. Wołoska 9a02-583 Warszawa

T + 48/ (22) 856 74 31F +48/(22) 856 74 [email protected]

RussiaZumtobel Lighting GmbHOfficial Representative OfficeSkakov aya Str. 17Bld. No 1, Off ice 1104125040 Moscow

T +7/(4 95) 945 36 33F +7/(495) 945 16 [email protected]

Norway Zumtobel BelysningHoffsveien 4

Postboks 1025 Hoff 0218 Oslo T + 47 22 0 6 50 5 [email protected]

SwedenZumtobel BelysningBirger Jarlsgatan 57113 56 Stockholm

T + 46 8 26 26 [email protected]

DenmarkZumtobel BelysningStore Kongensgade 1181264 København

T + 45 35 43 70 00

[email protected]

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