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Light as a Service: Pioneering lighting refurbishment

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The company REMONDIS shows that perfectly illuminated halls and a simultaneous reduction in energy consumption are by no means a contradiction in terms. At its Bad Essen site, the family-run company, which is active worldwide in the fields of recycling, water management as well as municipal and industrial services, has converted the existing metal vapor lamps in favor of modern, intelligently controlled LED lights. In this context, the lighting refurbishment in Deutsche Lichtmiete’s Light as a Service concept is setting the trend for the entire group.

“Before the retrofit, there were only two states: light on or light off. Most of the time, the lights were on, from 5 a.m. until closing time, even if there was no one in some work areas or daylight would have been sufficient.”

– Heike Redenius, Branch Manager in Bad Essen

Nevertheless: the lighting situation was not really satisfactory at any time of the day in the three halls of the property, which has been owned by the REMONDIS Group since spring 2020. “The lighting was based on outdated metal halide lamps that had not originally been installed for our fields of activity,” explained the branch manager. In the halls, two immense baling presses are used to process paper and plastic waste. There are also extensive workshop and storage areas. Heavy truck traffic is the order of the day.

Accordingly, clean and good illumination of driveways and assembly areas is essential. “The workplace directive provided for an improvement in illumination. At the same time, we no longer wanted to consume energy unnecessarily,” says Redenius. Sustainability and resource conservation are key pillars of the company’s philosophy, and not just in waste and residual material handling. “Our own actions are also constantly under scrutiny,” says the branch manager. “This starts with regular training of truck drivers in fuel-efficient driving and extends to energy-efficient management of the real estate used by the company.” Lighting plays an important role in this context.

More light, lower costs

The change in technology in Bad Essen clearly illustrates the potential of a lighting refurbishment: before the retrofit, 400-watt metal halide lamps provided light more badly than good. The new, modern lighting concept is based on concept light® 198 watt LED high-bay luminaires and a small number of concept light® III 340 LED high-bay luminaires, resulting in perfect illumination of all areas and a significant increase in workplace safety. “All specifications of the workplace directive are more than met,” says Redenius. The LED luminaires are products manufactured by Deutsche Lichtmiete in Germany. Heike Redenius appreciates the fact that they are even repairable and can be recycled. “Attributes that fit well with us,” says the branch manager.

Lighting control enables additional savings

Of note is the new lighting system’s intelligent, radio-based NEDAP control system, which not only offers every convenience, but also the possibility of saving an additional 30 percent or so of energy. In this way, the light coming in through the skylights can be used in a targeted manner. That is, depending on the incidence of light from outside, only as much artificial light is contributed as is needed for the desired illuminance. The radio control system from NEDAP also provides REMONDIS with an uncomplicated platform for monitoring data and records, for example, actual switch-on times and consumption. In addition, a new group switching system was installed so that the lighting in individual areas can be flexibly influenced manually as required.

Lighting refurbishment leading the way

The retrofit, including complete rewiring, was completed in just two weeks. All steps, from the lighting design and installation of the luminaires to the programming of the lighting control system, were in the hands of Deutsche Lichtmiete, which coordinated closely with the staff on site so as not to disrupt ongoing operations. “The planning and implementation were very professional, there were no restrictions whatsoever,” confirms Redenius.

For the branch manager, the fact that the company benefits from Deutsche Lichtmiete’s all-round carefree package with no investment whatsoever is also groundbreaking for other locations of the Group, for which Bad Essen serves as a role model. Instead, the company pays a monthly rental rate that, thanks to the considerable reduction in energy consumption, is significantly lower than the previous total lighting costs.

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Staying grounded even at altitude

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During a demonstration run as part of the DGUV “Aerial Work Platforms” trainer training course, Matthias Müller forgot to test the emergency stop function, got stuck with the scissor lift on several cones and hit his head on a roof beam of the training hall. The academy director did a lot of things wrong during the demonstration – and thus everything right. After all, his goal was to train the participants to evaluate test rides in every detail. This will be part of their daily routine after receiving their certificate. 

Comprehensive starter package

After several days of theoretical and practical training at the modern “Campus M – Home of Safety.” at the company’s headquarters in Blaustein, they are allowed to instruct and train operators of aerial work platforms and issue certificates of competence in accordance with DGUV Principle 308-008 – for telescopic and truck-mounted platforms and vertical lifts, among other things. The newly qualified trainers can also carry out annual follow-up training, and the company also provided them with a start-up package containing presentations and documentation aids for their own training. 

Designing driving courses

The training also included information on legal requirements for aerial work platforms, on liability and responsibility, instruction in technical basics and the various types of construction and drive, traffic regulations and traffic routes, and the design of driving courses. For Matthias Müller, whose academy also conducts the trainer training in accordance with the IPAF Handbook and in coordination with IPAF Germany, it is clear: “The need to train qualified trainers for MEWP operators arises both from the high risk potential during use and from a large number of relevant regulations.”

Guidance on moderation

For Miriam Winter of “Hessen Mobil,” this was a wealth of information. By taking on new tasks, the employee of Hesse’s road and traffic management department is entering completely new territory for her with the certificate – and immediately felt comfortable at the training as the only participant: “The exchange with colleagues was very good for me. I was able to take away some concrete tips.” In addition to the practical practice runs, it was also important for her to learn how to moderate instruction: “At AST, I learned how to lead a group, teach it, and get it excited about a topic.” Siggi Kern, on the other hand, is already an “old hand” in the broad field of aerial work platforms. But for him, too, there is always something to learn: “For me, it was important to get into the depths of the legislation in addition to the practical instruction. This allowed me to learn more about the high responsibility of employers and their concern for the physical integrity of employees.”

But one thing is clear: MEWP operators must also always be mindful and prudent, and learn that even at heights, you should always stay grounded. 

Occupational safety rethought

The company is one of the leading engineering firms for occupational health and safety in Germany and operates Campus M “Home of Safety.”, one of the most innovative training centers for occupational safety in Germany. The company offers an extensive seminar and training program, including virtual reality simulators. The focus is on practical training and further education and trainer certification in the field of safety management and technology – also available as an e-learning offering on request.

Fire protection management and company certifications round off the range of services. The training program, as well as the company itself, are ISO 9001 certified. Founded in 2003 by Angelika and Matthias Müller, the company now employs around 15 people who rethink the area of occupational safety on a daily basis and thus help to make the working lives of many people safer every day.

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Measurement, Instrumentation, Control & Automation Mechanical & Thermal Processes News Processing Technologies

Inauguration of the modern corporate campus in the greater Houston area

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Endress+Hauser has invested $34 million in a modern corporate campus near Pearland, Texas, in the greater Houston area. A large new training center, office space for 110 employees, a calibration laboratory and a repair shop have been built on 112,000 square meters. The new building strengthens the Group’s presence in the Gulf region.

Located in Pearland, Texas, the building is in the heart of the economically strong Gulf of Mexico region. “The expansion reflects our strong roots in the USA. It demonstrates our proximity to our customers and helps us to serve them even better in the future,” said Matthias Altendorf, Group CEO during the dedication ceremony on October 26, 2021.

Training facility for customer training

The new campus features the largest process training unit in the U.S., with 200 pieces of equipment and seven tanks, as well as a laboratory for metrology and process analytics. Local customers and partners can learn how to use modern measurement and automation technology here in customized training courses.

In addition, the campus is equipped for the accredited calibration of instruments for flow, temperature and pressure measurement. These can be carried out both in the laboratory and with a mobile calibration system at the customer’s site. A service workshop completes the range of services.

Sustainable construction in regional style

When planning the campus, the company placed great emphasis on sustainability. The building is already the fifth in the U.S. to be certified according to LEED (Leadership in Energy and Environmental Design) standards for environmentally friendly construction. In addition, regional materials were used in the interior and exterior to reflect Texas architecture.

Cross-company collaboration

The campus provides space for 110 employees. In addition to Endress+Hauser teams, the new building also houses the gas analysis business unit, the laboratory analysis specialists of subsidiary Analytik Jena, and regional sales and service partner Vector Controls & Automation Group.

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Ingredients & Auxiliary Materials Measurement, Instrumentation, Control & Automation News Processing Technologies

Decanter for leading paper and packaging manufacturer in South Asia

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Two CF 8000 decanters have now been supplied by GEA to ITC Paperboards and Specialty Papers Division in Bhadrachalam, India. The decanters support the modernization and new construction project.

The Paperboards and Specialty Papers Division is a company in the paper and board industry in South Asia. Modern recovery boilers will be installed at the site to improve the ash handling process. The two new CF 8000 decanters are important components of the ash leaching stage of a modern Chemical Recovery Boiler.

The advanced chemical recovery boilers are not only an integral part of the pulp recovery process, but also generate electricity and steam for the entire mill. This project is being carried out by Valmet, the world’s leading developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. Valmet, in turn, had contracted GEA to supply the CF 8000 decabnters as part of this overall project.

Serves as immediate and later as long-term solution

The company has already delivered the two decanters. As a first step, they were initially installed to support the three existing, old recovery boilers. When the new boiler is ready, the ash leaching system, including the two decanters, will be connected to it. The installation of the decanters so far is therefore initially an interim solution, but one that will allow ITC to continue production without interruption and without interruption.

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