Production hall of the future

Zumtobel strengthens digitalisation and circular economy with smart lighting refurbishment

#1 Refurbish: From Fluorescent Lamp to LED. From analog to digital.

In the underground production hall with limited natural light, the modernized lighting ensures optimal production and working conditions.

The installed T16 TECTON luminaires had reached the end of their lifespan and were replaced by new TECTON rails with nearly 230 TECTON C luminaires of the current generation. Around 75 additional sensors detect presence, room temperature, and humidity.

#2 Repair: Gentle dismantling. Sustainable value retention.    

While the existing luminaires and old ballasts from production hall 8 were separated into their material components and properly disposed of, the TECTON rails in the space were dismantled and reused. They are part of a comprehensive ReUse project in collaboration between Zumtobel and carla Vorarlberg, a social enterprise of Caritas.

#3 ReUse: For tried-and-tested tracks and lights.

On-site in Altach, the white-coated support rails were hand-cleaned and inventoried. This approach also allowed for a good assessment of the optical quality: "Of course, an industrial application like in our production hall 8 leaves traces of use on the rails," says Zumtobel Group Sustainability Manager Ines Göbel. Due to the distance from the viewer and the high-quality illumination, minor scratches and discolorations are hardly noticeable.

New standard for wireless lighting and building management

The conversion from fluorescent to LED and from analogue to digital took less than two weeks. On the one hand, this was due to the possibility of converting in parallel with ongoing operations. On the other hand, the well thought-out structure of the TECTON continuous-row lighting system, whose modular design was already exemplary for the entire industry when it was launched on the market more than 20 years ago. TECTON is quick and easy to install and dismantle. With its 11 poles, the TECTON track can also be flexibly adapted to different areas of application.

Zumtobel has installed new TECTON tracks with almost 230 TECTON C luminaires of the latest generation. In addition, there are around 75 sensors, which register presence, room temperature and humidity in production hall 8. Up to four luminaires are each controlled by one lighting control sensor.

Heating, ventilation and air conditioning can also be controlled

Keyture‘s radio-controlled building management system is based on a mesh network with Zigbee 3.0 Open Standard and communicates with a cloud. Thanks to the open communication standard, sensors from a wide range of manufacturers can be integrated into the Keyture network. Compared to basicDim wireless, which is a wireless solution that only controls the light, Keyture can be connected to other building systems such as HVAC (heating, ventilation, air conditioning). This opens up additional possibilities for improving building comfort and energy balance. Keyture has a wide range of APIs (Application Programming Interfaces) to ensure the best possible integration into existing operating processes and maximise efficiency.

„Using the data from our fully digitized lighting management system, we are able to intelligently reduce energy consumption in Hall 8 by automatically controlling lights based on room occupancy. Additionally, thanks to the switch to LED lighting, we have been able to save more than 75 percent of energy.“

Bittner, Head of Application Industry bei Zumtobel

Breaking new ground, gaining new insights

A project exploring numerous avenues for sustainable and future-proof lighting solutions: state-of-the-art LED luminaires and a new digital lighting management system by Keyture make the Zumtobel production hall 8 even more energy-efficient and contribute to rapid amortisation.

With each project that tests gentle dismantling and re-use processes, the standardisation and professionalisation of circular processes in the lighting industry are enhanced.

Zumtobel enters targeted partnerships with companies that share similar values and operate sustainably themselves.

The company's internal Circular Design Rules are consistently applied to design luminaires and lighting solutions from the outset for the circular economy. In this regard, the TECTON lighting system is a true pioneer within the product portfolio: over 20 years old, yet still open to new applications and additions.