300+

LED LUMINAIRES

ZPS – FOUNDRY, a.s. – SPECIALIST IN GREY AND DUCTILE IRON CASTINGS

ZPS – FOUNDRY, a.s., a leading manufacturer of grey and ductile iron castings, modernized the lighting in its main operations – the roughing shop, foundry, and sand plant. By installing top-of-the-line doublepower!! SKY and SKY TaMax fixtures, the company achieved nearly 84% energy savings and a return on investment within just one year.

Case study

About the company

ZPS – FOUNDRY, a.s. is among the leading manufacturers of high-quality grey and ductile iron castings, ranging in weight from 30 kg to 12 tons. The company provides a complete service – from material consulting and the production of pattern equipment to manufacturing, machining, heat treatment, and surface finishing, all the way to the delivery of castings. Thanks to its ability to meet specific customer requirements, it has long maintained a reputation as a reliable partner in the market.

Implementation

Between October 2022 and January 2023, lighting modernization was carried out in key production areas:

• Roughing shop – 7,500 m², installation height 18 m
• Foundry – 6,500 m², installation height 20 m
• Sand plant – 700 m², installation height 25 m

The original lighting system was replaced with modern LED technology:

• 284 SKY luminaires
• 30 SKY TaMax luminaires

In the roughing shop, an intelligent Helvar control system with daylight-based regulation was additionally implemented to further maximize energy savings.

Results

• Annual energy consumption: reduced from 0.93 GWh to 0.15 GWh
• Energy savings: ~0.78 GWh/year (≈84%)
• Return on investment: 1 year