Schumacher Packaging
Case study Schumacher Packaging
Modernization of Lighting at the Schumacher Packaging Production Facility
Schumacher Packaging is one of the largest manufacturers of corrugated and solid board packaging in Europe. The company offers its solutions for the food, chemical, cosmetics, logistics, and e-commerce industries. A key focus of the company’s activities is its commitment to sustainable development and corporate social responsibility. Schumacher Packaging uses natural raw materials in the production process, allowing the creation of products that can be recycled later. These and other measures undertaken by the company for the benefit of the environment, the local community, and its employees contribute to creating a friendly business environment. To this end, the company systematically introduces innovative solutions, one of which is the modernization of lighting and the replacement of light sources with modern LED lighting.
Production halls, warehouses, office spaces
A maintenance-free system for controlling light intensity at workstations and walkways
High temperatures ranging from 35 – 50°C
Challenges:
No downtime during installation
High temperatures ranging from 35 – 50°C
Increasing intensity while reducing costs
Extended warranty
The nature of the actions taken for the benefit of employees, society, and climate protection was one of the reasons that led the company to replace its lighting with LED. Savings through reduced electricity consumption and a maintenance-free lighting control system for workstations and traffic routes are the main goals of the modernization. As a result, the sense of security and comfort for employees has increased. Additionally, the investor desired a long warranty for the selected lighting. Comprehensive support in every phase and service after the investment’s completion were of great importance during the execution of the investment.
With the comprehensive modernization of the lighting system, Schumacher Packaging was able to meet its sustainability goals and continue to maintain high standards for the benefit of employees, society, and the climate.
Jakub Kuberka
Head of Domestic Sales at Luxon LED
Lighting design concept
The investor wanted to reduce electricity costs while being able to flexibly control the lamps. Increasing the illumination at workstations was also one of the investment goals. Therefore, a lighting control system with sensors for light incidence into the rooms was developed, and the entire area was divided into zones. This was to make the lighting system more flexible and optimize its operation. Summary of Investments: We installed over 800 LED luminaires during the implementation. The modernization included the use of Ultima HPT and industrial lamps as well as office lamps, baton, downlight, backlight, and over 40 Cordoba outdoor lighting fixtures. Additionally, the company’s premises lighting was included in the project. For the outdoor lighting of Schumacher Packaging, pole-top luminaires and facade lighting were used.
Industrial 6.0 IP 65 180 lm/W
With a length of 150 cm, this luminaire is ideal for industrial applications and offers outstanding performance and efficiency as an alternative to conventional 2x58W fluorescent lamps.
Ultima 3 HPT up to 70°C, 170 lm/W
Reliable industrial luminaire for extreme temperatures from 35 to 70°C, offering flexibility in diffuser selection, power range from 42W to 145W, and advanced control systems.
Cordoba LED
Luminaires with a power range of 81-149W for city streets, equipped with control systems, various lenses, and a 10-year warranty.
Scope of Cooperation:
Lighting audit
Lighting design concept
LED luminaires
LED lighting control system
Installation
In the production halls of the Schumacher Packaging plant, there are various work areas. The comprehensive modernization of the lighting affected all production and warehouse halls as well as the office spaces. At each of these locations, the work had to be carried out so that the production process was minimally disrupted and the needs of the employees at the workstations were considered. Therefore, we first conducted a detailed lighting audit, during which we collected all necessary data, and based on this data, we subsequently created a lighting design concept. Planning and installation took the existing system into account, leading to additional savings for the investor. Due to the size of the facility, the modernization was divided into three phases.
The project covered areas including the production halls. In areas where corrugated and solid board packaging is manufactured, high temperatures of 35°C to 50°C prevail. In such places, aluminum luminaires had to be used to withstand these conditions, including their maintenance for the next 8 years. The warehouse halls and the social-technical areas adjacent to the halls were other project areas where we implemented the new LED lighting.
Implementation effects
Average annual savings of 28,000 €
Return on investment after 1.5 years
Warranty for the luminaires
Check the Client Testimonials
Tomasz Kroczak
It was particularly important to us that the project was carried out holistically. They planned and implemented the entire lighting renovation and supported us at every stage of the project.
Tomasz Kroczak
Leiter der technischen Abteilung Schumacher Packaging
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