Theysohn Formenbau GmbH
Case study Theysohn Formenbau GmbH
Theysohn Formenbau GmbH is part of the Boryszew Group, which is active in the automotive market, the chemical industry, and the metal industry.
Theysohn Formenbau GmbH focuses on the production of metal molds required for the production of plastic parts. It has a highly developed and technologically advanced machine park, enabling it to offer its customers unique, high-quality products with various shapes. We conducted a lighting audit at three German branches of the company, paying particular attention to the impact of lighting on work safety and operating costs. We proposed specific solutions leading to changes in this area, which the customer decided to implement.
Production hall
Manufacturing of metal molds
Reduction of energy costs
High temperatures on steep slopes, especially in summer
Challenges:
Modernization during operation without blocking the production process
High temperatures up to 60°C
Remote-controlled luminaires
LED luminaires with high-quality components for a long lifespan
The change of luminaires had to be carried out in older production halls, which get extremely hot at the ceiling, especially in summer, and work is conducted at high temperatures. The customer expected light sources that are characterized by slow degradation and a long lifespan. They should be made of high-quality components to ensure durability and positively impact the reduction of energy costs. Additionally, the customer expected innovations related to automation and remote control. The modernization of the LED lighting in the production facility had to take place during working hours without disrupting the manufacturing process.
“It really convinced us that we received everything from one source, that we work not with a dealer, but with the manufacturer, the dealer, and also with the company that produces itself in Europe.”
Henning Strepkowski
Safety and Maintenance Manager
Lighting design concept
We conducted a lighting audit at three German branches of the company, paying special attention to the impact of lighting on work safety and operating costs. We proposed specific solutions leading to changes in this area, which the customer decided to implement. The luminaires were installed by us, including new wiring and a cabinet that required replacement. Considering the conditions in the halls and customer expectations, we chose the Ultima LED lamps in the PRO version, which are resistant to high temperatures, with an IP65 tightness coefficient and a low UGR coefficient to increase work and safety comfort. The lighting was equipped with the Helvar control system. The control system takes into account the division into zones, with light sensors installed in each. The control panels enable management of lighting, selection of light scenes, switching on and off. The system is complemented by the USEE panel, allowing control from the browser level. Additionally, it reports failures and monitors energy consumption in real-time.
Ultima LED 140 lm/W, up to 65°C to 70°C, 170 lm/W
Ultima LED is a versatile industrial lighting from 21W to 260W, ideal for production halls and warehouses. Thanks to various power options and a lifespan of over 135,000 hours, it is an excellent choice for a variety of applications.
Lighting remote control thanks to the uSee interface
The lighting was equipped with the Helvar control system. The control system takes into account the division into zones, with light sensors installed in each. The control panels enable management of lighting, selection of light scenes, switching on and off.
LED investment analysis
For the lighting design concept, we created a detailed financial investment analysis, which showed an estimated return on investment of 1.5 years and a cost reduction of 65%.
Implementation effects
Savings of almost 50%
Reduction of allocated power for lighting per year
Less CO2 emissions
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