Volkswagen Commercial Vehicles opened a new production plant in the Polish city of Wrzesnia at the end of October 2016. The factory manufactures the latest generation of the Volkswagen Crafter and the similar TGE model from MAN. The site, which covers an area of around 220 hectares, has the capacity to produce up to 100,000 vehicles per year and incorporates a modern paint shop and halls for bodywork construction and assembly, as well as a supplier park with logistics operations.
Thanks to a full LED solution from Zumtobel, the factory has established itself as a leader in lighting efficiency within the VW Group.
Zumtobel supports the 'Think Blue-Factory' concept
Zumtobel was awarded the contract for this major project in Wrzesnia in 2015 following the submission of a detailed lighting concept. Alongside luminaires and controls for the assembly and production halls, the complete solution includes efficient lighting for the offices, high-bay storage facilities and outdoor areas. Safety lighting also represented a key cornerstone of the project.
Zumtobel was in close contact with specialist planners from Volkswagen Commercial Vehicles throughout the implementation phase, helping the Austrian lighting solutions supplier to precisely fulfil the specific requirements of the client. Initial Volkswagen planning was based largely around conventional lighting, but efficiency calculations and the technological progress of LED technology at Zumtobel soon convinced the planners to realise the entire project with LED.
The decision prompted VW to classify the new production facility as a 'Think Blue-Factory'. This programme is designed to encourage plants to use resources more efficiently, reducing emissions and energy usage while minimising both water consumption and waste. “We are delighted that Volkswagen Commercial Vehicles has opted for a complete LED approach. Together we have been able to create one of the most efficient production plants in the VW Group in terms of lighting,” explained Frank Oevermann, Key Account Manager Automotive at Zumtobel.
Matthias Strutz, Electrical Power Supply Planning at Volkswagen in Wolfsburg, added: “The new factory represents a clear statement in terms of environmental protection. We are really benefitting from the decision to use only LED - both ecologically and economically. LED solutions extend the service life and cut maintenance and operating costs, while at the same time ensuring a constant lighting intensity over the entire service life.”
Lighting solution in detail
The largest part of the project is taken care of by the TECTON continuous-row system, which reduces energy consumption by 50% compared to T16 trunking. A total of 16,000 TECTON C LED luminaires are installed over a length of around 40km. This continuous-row luminaire is optimised for a variety of different racking and surface lighting tasks, providing a suitable solution for the dedicated Volkswagen Crafter manufacturing and assembly facilities.
The current conducting section is mounted in the TECTON trunking, enabling the versatile rail to offer seamless functions such as power supply, lighting controls and connection to the emergency lighting network. The CRAFT high-bay fitting used by Zumtobel in the paint shop and higher halls can be quickly and easily installed on the TECTON system.
Based on 15,000 continuous-row 40W LED luminaires and 6,000 operating hours, Volkswagen Commercial Vehicles is now saving 3,420MWh and 1,920 tonnes of carbon dioxide (CO2) each year at the Polish plant.
The offices feature the recessed MIREL evolution luminaire and the PANOS downlight series, which ensure uniform illumination of the working areas and create precise accents that accentuate the interior architecture.
R2L2 LED lanterns and ForceLED fittings from Thorn light the car park and exterior façade. The high performance optics utilised in the R2L2 street lantern offer excellent energy efficiency and a choice of distributions for precise light control without wasteful stray light. The compact, dust-tight and moisture-proof ForceLED solution incorporates an aluminium housing for added resistance and supplements the general exterior illumination of the building with pleasant accents.
The ONLITE RESCLITE from Zumtobel has been trusted to highlight the escape routes. In line with EN 1838, the luminaire provides the necessary orientation in the event of an emergency and also offers anti-panic lighting. The emergency lighting is monitored by LITECOM, a lighting management solution from Zumtobel Group Services (ZGS).
Additional lighting tasks are carried out by products from Zumtobel’s PERLUCE and ONDARIA series and the Thorn Satin range, alongside the KXA-2 and KXB explosion-proof linear luminaires. As a technology partner, Tridonic has supplied component solutions such as drivers and LED light sources for the luminaires.
A specific Constant Light Output (CLO) setting was configured for the entire luminaire installation during the manufacturing stage. The CLO function, which is now standard for all industrial luminaires used by Volkswagen, ensures a uniform reduction in the luminous flux over the stated lifetime.