Zott Polska Sp. z o.o.
Case Study Zott
Comprehensive lighting modernization in Zott’s production facility and warehouses, including replacing traditional luminaires with energy-efficient LEDs designed to operate in low temperatures.
Zott, a leader in the dairy product market in Central Europe, decided to replace the lighting in cold stores, freezers, and unloading areas at its Opole plant. The main challenges included adapting the lighting to operate in low temperatures and increasing energy efficiency. The modernization involved replacing 27 traditional 400W and 250W luminaires with Highbay LED 120W and 180W luminaires, as well as introducing wireless control for Industrial LED luminaires in unloading areas. The project resulted in significant energy savings, and the lighting was fully adapted to the stringent requirements of the food industry.
Production facility and warehouses
Food production
Operation in low temperatures, high luminaire tightness, wireless control
Challenges
Lighting adapted to operate in cold stores and freezers
High requirements for luminaire tightness and resistance to low temperatures (0-10°C)
Automation of lighting in unloading areas
Increasing energy efficiency and cost savings
Dairy product manufacturing required creating appropriate storage conditions for products in low temperatures, affecting cold stores and freezers. The luminaires used had to meet strict sanitary standards, have high tightness, and perform efficiently in temperatures from 0 to 10 degrees Celsius. Another goal was to automate lighting in unloading areas to optimize energy costs and improve the efficiency of the entire lighting system.
Lighting concept
The project involved replacing 27 traditional Highbay 400W and 250W luminaires with High-Bay LED 120W and 180W luminaires with a color temperature of 6500K and CRI>70. Additionally, Industrial LED luminaires with OSRAM Duris E5 diodes were installed in unloading areas, providing 4000K color and high CRI>85. The luminaires were connected to a wireless control system that works with daylight and motion sensors, enabling automatic adjustment of light intensity to current needs.
High-Bay LED 120W and 180W
Used in cold stores and freezers, these high-efficiency luminaires operate in temperatures ranging from 0 to 10 degrees Celsius.
Industrial LED
Luminaires used in unloading areas, equipped with OSRAM Duris E5 diodes. They provide 4000K color and high CRI>85, meeting the standards of the food industry.
Wireless Control System
Installed in unloading areas, it automatically controls lighting based on daylight intensity and motion detection.
Scope of cooperation
Inventory
Audit
Design
Control system
Luminaires supply
Installation
We started with an inventory and audit of the facility to identify areas requiring modernization. The key goal was to ensure luminaires suited to operation in cold stores and freezers, where high tightness and resistance to low temperatures were necessary. The modernized Highbay LED luminaires met all sanitary standards and provided longer lifespan with lower energy consumption.
In the unloading areas, Industrial LED luminaires were installed and integrated with a wireless control system. By using daylight and motion sensors, the lighting automatically adjusts, significantly reducing electricity costs in the facility. The luminaire installation process was smooth, and the client achieved the expected savings.
Implementation Results:
reduction in electricity consumption
ROI (Return on Investment)
luminaire resistance to low temperatures
Check the Client Testimonials
Robert Szymczak
The Zott warehouse operates daily for many hours, generating high costs. By replacing metal halides with Highbay luminaires, we save over 50% of electricity. Therefore, we plan to use LED lighting more widely.
Robert Szymczak
Zott Polska Sp. z o.o.
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