Skoda Car production plant, Mlada Boleslav Intelux controllers for lights intelligent management in a factory
Intelux NG controllers for internal lighting Skoda Auto, Mlada Boleslav (Czech republic)
Background

In 1997, AKTÉ Ltd, distributor of INTELUX products in the Czech Republic, started working in the SKODA CAR production plant in Mladá Boleslav on a project to restructure the lighting plant in the Hall V17. We are talking about an area of 35.000 m2, previously served by 1700 lighting fixtures, equipped with mercury vapour lamps of 400 and 1000 W. The total installed power was 950 kW. On this occasion, apart from supplying lighting fixtures and control system, AKTÉ also designed and installed the plant. The project saw to replacement of lamps and lighting fixtures as well as installing an energy saving lighting control system. The system had to reduce artificial light in proportion to available daylight making sure that required lighting levels (according to the needs of the various production departments) were maintained and to automatically turn off lighting plant when required lighting level could be totally guaranteed by available natural daylight.

The solution

AKTÉ decided to entrust plant control to Intelux controllers and in this way satisfy the above mentioned needs. The first job was to replace the mercury vapour lamps with metal iodide and sodium vapour lamps. This choice meant that the number of lighting fixtures was reduced by75%, and the corresponding installed power was reduced by 60%, giving way to the first great savings. Afterwards, with the installation of the Intelux system, the overall energy savings were increased by up to 72% and savings on maintenance costs reached up to 68%.

The benefits

The combination of energy saving and savings related to reduced maintenance costs linked brought the overall investment return time (for this plant) to under three years, as shown by data given below:
 

 

Exisiting
state

New
project

With
Control

Intelux
savings

 

 

(a)

(b)

(c)

(a) - (c)

Working hours

h/year

5.000

5.000

5.000

 

Lighting level

lux

200

500

500

 

Number of lamps

parts

1700

440

440

 

Overall Power

kW

950

374

374

 

Energy consumption

kWh/year

4.750.000

1.870.000

1.309.000

561.000

Energy costs (*)

EUR/year

178.125

70.125

49.087

21.037

Maintenance expenses

EUR/year

35.400

19.500

11.000

8.500

Total expenses

EUR/year

213.525

87.625

60.087

29.537

Installation cost

EUR

 

160.000

160.000

 

Lamp cost

EUR

 

180.000

180.000

 

Cost of INTELUX system

EUR

   

100.000

100.000

Total investment

EUR

 

340.000

440.000

100.000

Total Saving (a) - (c)

EUR/year

   

153.438

29.537

Pay back time

years

   

2,9

3,4


(*) Energy cost: 0,0375 EUR/kWh