Simoldes Plasticos is the biggest manufacturer of synthetic casts in Europe. The Group is present on the market for almost 60 years, the production plant located in Jelcz-Laskowice is operating since 2004 and employees almost 300 workers. The company is an expert in the field of castings and injection molds. In 2006 a set of corporate rules was prepared and implemented in branches all around the world. The 5S methodology was officially incorporated: sort, set in order, shine, standardize, sustain. The 5S methodology plays also an important role in our actions – during the energy audit, light design and fixture upgrade.

Modernization Benefits

Ikona zwrotu z inwestycji w oświetlenie po 3 latach - Luxon LED

Return on investment after modernization

Znaczek oszczędności 60% - Luxon LED

Annual energy savings after modernization

Ikona systemu sterowania oświetleniem DALI - Luxon LED

Lighting control system

The challenge

How to upgrade the lighting system during the production process?

The original fixtures were mounted high and manufacturing stoppages would generate substantial losses. Can we combine both? After the audit was conducted and we got familiar with company’s internal processes, we managed to prepare an elaborate plan. As mentioned the Customer could not stop the production, therefore our first task was to find a solution, which would allow both actions to be run simultaneously. The installation could not affect everyday tasks in the warehousing and production area. We decided that all replacement related work
should be conducted between 23:00 and 5:00. To ensure workers safety during the manufacturing process, special zones and grids were established. On account of a gantry, we needed to place a scaffolding, which allowed us to reach hard accessible places to mount the new lights. All actions were discussed and coordinated with the Maintenance Technician, to ensure safe work conditions. The upgrade took a month and was a huge logistic challenge to us and our Client.

Highbay:LED and Industrial:LED luminaires were chosen for the implementation, together with the DALI control system, which creates optimal lighting conditions and allows cost reduction on electricity.

Paweł Czerkawski

Technical director

The solution

Automated industrial fixtures

In order to reduce operating costs, we conducted a thorough audit and upgraded all fixtures in the storage depot and the shed area. The environmental conditions at the hall were specific, we decided to mount our Highbay fixtures with ceramic diodes, which are more durable than their plastic counterparts. Plastic diodes are less resistant to higher temperatures; their overlay can contain traces of silver, which can corrode in presence of sulfur. As a result, they can lose their lumen rating and the overall lifespan can be shortened. The applied ceramic diodes are better equipped to withstand higher environmental temperatures. What’s important their power factor (PF) is higher than 0,98.

The power factor tells us how much reactive power is generated by the fixture. The closer the value is to 1, the lesser consumption is to be expected. In result, energy expenses are lower. The Customer also did choose a modern light control solution. We implemented an intelligent lighting control system, throughout the whole facility, using Helvar’s industrial DALI solutions and additionally the halls were equipped with light intensity sensors. Due to a substantial presence of daylight, which enters the room through skylights, multi-sensors were installed.

What did the Customer gain?

Modernization benefits

  • Substantial savings thanks to the application of the DALI system.

  • Installation of industrial fixtures with a prolonged lifespan, confirmed by laboratory tests.

  • Usage of natural daylight and adjusting lightintensity through a network of intelligent sensors

  • Improved work conditions safety and ensuring the THD norms are met

  • ROI – only 3 years

Facility after modernization

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