The internationally networked energy company EcotecWorld plans and develops individual LED solutions and lighting systems in industrial dimensions. The combination of highly efficient luminaires and intelligent control creates brilliant energy and operating balances. This is made possible by precise light planning and simulation.

The light output, the lifetime and the energy efficiency of LED luminaires outshine all other common light sources. The energy-savings can be up to 80%. In addition, the costs for maintenance and replacement are significantly lower. The mercury-free LED tubes also score against neon tubes and energy-saving lamps. Considerable advantages – in the private and public areas, however, they are slow. A discrepancy that has already led politics to action: In order to support the broad market launch of LED in Germany, the German Federal Ministry of Education and Research (BMBF), for example, has launched the LED lead market initiative.

Industry has long recognized the benefits a long time ago for itself. No wonder, the huge saving potential of LEDs is particularly noticeable. In the automobile industry, as well as in the manufacture of mobile phones, laptops and cameras, the diodes have provided for a small revolution. The promises for the entire energy and environmental protection sector are high, as almost 20% of the world’s electricity consumption is caused by lighting.

Even if the technology is already very sophisticated, there is not yet the right LED solution for every application. In production plants the requirements are high and vary greatly depending on the industry. Consider, for example, hygiene regulations in food or animal farms. There is often still a lot of development-work to be done.

This is precisely where the energy company EcotecWorld from Uelsen in Lower Saxony, which specializes in the development of environmentally friendly solutions for energy generation and energy saving, is set up. The European and Asian branches are working on the challenge of how the environment and economic interests can be combined. In addition to solar and wind power, LED technology forms the third area of competence.

EcotecLED stands for an exclusive sales cooperation with the US Honeywell Group, which secures the exclusive distribution rights for the LED products in the German-speaking European region as well as the Benelux countries. The product focus is on highly efficient LED tubes, especially for car parks, material, logistics and production halls as well as retail areas and offices. “Especially in the case of energy-hungry lighting a lot can be achieved through a refurbishment. Globally, the worldwide energy consumption for lighting could be reduced by 40% – by the use of LED alone. At the company level, the savings are clearly visible in the balance sheet. New systems are amortized within a few years, “says Managing Director Holger Stegink, explaining the relationship between economics and ecology.

Illumination solution as required

But it is not just about selling existing products, lighting solutions are also developed completely as needed. This is the case for Emsland Stärke Logistics GmbH & Co. KG in the logistics warehouse of the main factory Emlichheim. In 2009 there was an urgent need for action: Only 35% of the lighting system was intact, a large part aborted and the exchange of tubes was very expensive. The Emlichheimers sought a complete renewal and contacted EcotecWorld.

“This is where all threads come together,” explains Achim Kip, Technical Director for LED, the constellation at EcotecWorld, “Honeywell and Ecotecworld have been investing in the research and development and production of state-of-the-art LED-lighting for years. Together, both companies developed a new LED-tube – consisting of a driver, the light source and new fixtures – which consumes only 23 W instead of the usual 58 W.

At the end of the development phase, a completely new, thoroughly tested product, which meets all the safety criteria of the food industry, stood. The luminaires were tested in the laboratories of DIAL and Zumtobel. The new LED-tube is one of the few products that have a German VDE-approval in addition to the standard CE-certificate.

After a prototype was available, it was possible to speak to the lighting manufacturers and how the new LED components could be integrated into existing T8 luminaires. For reasons of cost, the existing lighting system should be reused. With Reiss Lighting GmbH from Friedrichshafen the right partner was found.

Reiss Lighting’s IP67 luminaires are equipped with VDE-tested Honeywell LED tubes with a light color of 5000 K and a color reproduction of 70 Ra. The tubes are particularly resistant, protected against foreign bodies and very easy to maintain. In the logistics warehouse of the food company, they ensure the necessary hygiene and enable an optimal orientation.
With this solution, Achim Kip was finally able to develop an intelligent lighting concept with environmentally-friendly and energy-saving LED lighting along with a light-control system. The planning project was a building of 2.97 ha, divided into three halls, which in turn are divided into 24 fields. The old lighting system was switched by the hall. This means that 480 luminaires were in operation per hall. A particularly inefficient solution, especially since in a warehouse only certain points are controlled in a targeted manner.

The driving light

“Key idea, therefore, was the driving light”, Achim Kip illustrates the new solution for a light control via presence detectors with at least one device per field. The system is controlled by LEDs and presence sensors via a bus voltage supply from Honeywell, the PLS PEHA light control “MLS Digital”. The detectors are networked via a special two-wire twisted-pair cabling and are freely programmable. It is therefore basically possible to switch different and several fields via a detector. If someone enters or enters the hall, the lighting can be switched in a highly flexible cycle.
This efficient control was decisively supported by the use of the planning and calculation tools DDS-CAD and “DIALux”. Achim Kip, engineer for utility engineering, benefits from his long-standing parallel work as a CAD-planner for Arens KG. Here the DDS-CAD solutions Elektro and SHKL have been in active use since 2002. He has been working for several years on the job and knows exactly what is important for the electrician.

In the standalone BIM solution from Data-Design-System, Achim Kip was able to capture the hall-system as a 3D-building model and thus create a reliable planning basis. Using the bi-directional DDS-CAD interface to “DIALux”, the entire room geometry was then transferred to further light planning and calculation. Thanks to the precise technical data from the laboratory tests, the necessary information was directly available.

After completed lighting planning, the data can be completely transferred back to DDS-CAD, including the isometric lines. “The interface to DIALux works really smoothly,” Achim Kip recalls in retrospect. The extensive electrical installation with cable laying and cable calculation was also carried out in DDS-CAD. The length control was particularly useful in the planning of the buslines and the networking of the busdetectors, since a maximum length of 1500 m could not be exceeded to limit the voltage drop. The voltage drop function in DDS-CAD is able to dynamically monitor branched structures with graded cable dimensions. With every change or addition of a circuit, the software automatically determines the most unfavorable line segment.

A success-story

To get an impression of the LED light, a provisional test panel with light control was installed in October 2010. 18 Honeywell-Schuch-LED-lights with 23 Wh, switched via two HF presence detectors, were installed on the existing lighting system. After a successful test, the entire lighting system was finally renovated in 2013.
1.680 LED-tubes are installed in the halls; The energy savings in the year is almost 500,000 kWh. In the case of energy costs, this means a saving of 44,000 Euro/anno for Emsland Stärke Logistics GmbH. The flexible control options allow the plant to be adjusted exactly according to the specifications of the hall staff. In the high-frequency areas in which, for example, trucks are loaded and unloaded, this was set to 20 minutes, in the less-used fields the cycle is about 1 minute.

Rebekka Bude
Data Design System GmbH