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PowerLink lighting control system contours lighting toproduct manuacturers unique processes

When it comes to energy eciency, manuacturers are always looking or any edge they can nd, andcan spend a substantial amount o time searching every corner o their operation or ways to reduceenergy and cost. Facility management or the Menasha, Wisconsin, plant o Albany International Corp.

approached this challenge by working with Schneider Electric to devise a lighting control strategy thatcontours lighting use to the specic nuances o its manuacturing processes.

With manuacturing plants in 14 countries, Albany International manuactures paper machine clothing,a key component used in the production o paper products. Its Menasha acility, or example, makesorming abrics or the paper industry. Menasha acility management implemented an entire lighting retrotproject in 2002 and called on Schneider Electric to provide a solution to manage lighting requirements inits unique production environment. That solution was the Square D brand PowerLink NF2000G3 andNF3000G3 lighting control systems, which provided the appropriate type o lighting control based onthe dierent work areas in the acility, including specic areas on the manuacturing foor, along withthe oce area.

Application

Every abric thats manuactured in Albany Internationals Menasha acility progresses through the sameour-step process weaving, inspection, heat-setting/cutting and shipping perormed in our distinctwork areas. Thus, in order to more eectively manage energy use and costs, acility management realizedan all lights on or all lights o approach wouldnt be as ecient as contouring lighting usage to therequirements o the specic areas.

By implementing the Square D brand PowerLink NF2000G3 lighting system as part o a lighting retrotthat was originally ocused on changing out metal halide and T12 fuorescent xtures, the company is ableto manage the lighting schedules required in each work zone on the manuacturing foor. For example,an operator uses a touch-screen console to activate lights in the weaving and heat-setting zones,and then uses the same console to turn lights o when a project moves to the next zone. Conversely,lighting schedules are used in the inspection and shipping zones, with lights automatically turning onand o at set times. Thus, the company accrues substantial energy savings when lights are turned o inmanuacturing areas that are not in use. Additionally, a Square D brand PowerLink NF3000G3 controller

acilitates a lighting schedule in the oce area, while occupancy sensors turn lights on in the oce area isomeone works late or comes in early. Schedules or the parking lot lights are built into both controllers.

Objectives

Implement a lighting control system that maximizes cost savings

Take the approach that lighting should be separate and distinct rom other energy-supply circuits

Make the new lighting strategy easily transerable to other company acilities

Make the most oyour energy

SM

Industry

Product manuacturing

Objective

Contour lighting strategyto specifc nuanceso industrial acilitysmanuacturing process

Apply philosophy thatlighting should beseparate and distinctrom other energy-supply circuits

Increase energy andcost savings relatedto lighting

Facilitate ease o use o

lighting control systemor operators

Replicate existingacilitys successullighting control strategyto new acility

Solution

Square D brandPowerLink lightingcontrol systemNF2000G3

Square D brandPowerLink lightingcontrol systemNF3000G3

Benefts

Enhanced cost savingsthrough less requentlamp replacement

Energy savings byturning lights o inmanuacturing areasthat are not in use

More than $300,000 incost savings accruedthrough lighting retroft

Easy, amiliar touchscreen unctionalityor operators

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295 Tech Park DriveLaVergne, TN 37086

Tel: 1-888-SQUAREDwww.squaredlightingcontrol.com

08-08 tk

Solution

Since the lighting retrot was implemented in 2002, Albany Internationals Menasha acility hassaved more than $300,000, including $65,000 in the rst year, much o which can be tied to theSquare D brand PowerLink NF2000G3 and NF3000G3 lighting control. The strategy was so successulthat it was later applied to Albany Internationals new acility in nearby Kaukauna, Wisconsin, whichopened in 2007 and uses the Square D brand PowerLink NF3000G3 web-enabled lighting control system.

The lighting control implemented at the Menasha acility also creates cost savings in other areas, includinglamp replacement. Most lamps are rated or 25,000 hours, and keeping lights o up to one-third o the

time extends the relamping cycle considerably. This also means workers are dispatched less requentlyor lamp replacement.

A large acility like ours typically includes a number o manuacturing cells and warehousing, saysDan Steves, Menasha acility manager. The old school way o lighting was to treat it as i it were one giantwarehouse, where the lights were all on or all o. That doesnt make sense. We applied the philosophythat lighting should be distinct and separate rom other energy-supply circuits. What we ended up withwas actory and oce areas that have properly designed lighting systems.

For more than 100 years, Schneider Electric has been a pioneer in manuacturing innovative productsthat are tailored to the demanding specications o our customers. Our products, solutions and servicesare present at every link in the energy value chain or the building, inrastructure, industry and residentialmarket to ensure perormance and comort, while taking into account environmental issues. Backed bya global organization with one o the strongest distributor networks in the U.S. and around the world,

Albany International can rely on Schneider Electric to enhance its energy eciency.

Benefts

Cost savings through contouring o lighting to specic areas and processes

Automatic on/o in appropriate areas and easy operator interace in others

Easy transer o the lighting control strategy to other manuacturing acilities

Schneider Electric - North American Operating Division

Document Number 1210AC0801

The Square D brand PowerLink NF3000G3web-enabled controller that acilitates the ofcelighting schedule in Albany International Corp.sMenasha acility.

Curt Swinord, loom operator at Albany International Corp.sMenasha acility, prepares to turn a looms overhead lightso using a touch screen display.

years as a pioneer inmanuacturing innovativeproducts that are tailored tothe demanding specifcationso our customers.

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