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Pikolin benefits twice from SCADA and Energy Management

What's better than benefiting from a solution once? That's right – benefiting from it twice. Discover how Pikolin achieved that in a brand-new production facility. Powered by SIMATIC SCADA and Energy Management, it consumes less energy and yet has more production capacity.

Challenge: Efficiency, productivity, and sustainability

Pikolin is the leading manufacturer of sleep products in Spain. Its new facilities in Zaragoza, Spain, are Europe’s largest and most advanced industrial complex in the sleep products sector, as well as one of the largest in the world. Pikolin is committed to being environmentally responsible and has recently received certification for energy management in accordance with ISO standards 14001 and 50001. The move to the new facility offered a unique opportunity to design all plants and processes from scratch to meet the highest standards for productivity, efficiency, and sustainability.

To ensure continued compliance with ISO 50001 and enable continuous improvements in operations, Pikolin chose SIMATIC SCADA and Energy Management.

A solution that simply pays off

Less electrical energy

Pikolin was able to reduce its power consumption by 14% per square meter across the company.

Less natural gas

In addition, gas consumption in the production area was reduced by 40% per cubic meter.

Higher production capacity

At the same time, Pikolin was able to increase production capacity by almost one third.

A scalable solution for managing production and energy

Pikolin wanted to be able to achieve full control and visibility of all processes in its new facility. For this purpose, the company first implemented a SIMATIC WinCC V7 SCADA system, complemented by a SIMATIC Energy Manager PRO energy management system, which helps Pikolin comply with ISO 50001, and SIMATIC HMI operator interfaces.

We have always been a reliable partner and supplier, so the electrical installations use primarily Siemens products and solutions, with various SIMATIC controllers and SENTRON PAC measuring devices on the production floor. All the data are linked to a SIMATIC WinCC V7 SCADA system running in a virtual environment. This system is complemented by SIMATIC Energy Manager PRO for monitoring and analyzing energy and media consumption.

Grupo Pikolin, Spain: Dedicated to sleeping comfort

Pikolin began as a small mattress factory in 1948 and is now the leading manufacturer of sleep products in Spain. With a turnover of €446 million, it is ranked as the second-largest European group in the sleeping comfort sector and is the market leader in Spain and France. The group employs around 3,000 people in its nine production plants in Europe and two in Southeast Asia.

At Pikolin, quality comes first: the company has established global quality systems for the whole company, as it views quality control as a dynamic and integrated process for monitoring the company at all levels. On January 26, 1996, Pikolin became the first company in the sleep products sector to be awarded the ISO 9002 Quality System certificate by AENOR, the Spanish association for standardization and certification.

A showroom with Pikolin mattresses. The company name is displayed in large letters.

Dedicated to quality

In June 2003, after the standard was updated to ISO 9001:2008, Pikolin updated and improved its entire quality system. Additionally, Pikolin S.A. recently implemented an ISO 14001–compliant environmental management system, which has also been certified by AENOR. In the new manufacturing facilities at the Plataforma Logística of Zaragoza (Plaza), all Pikolin’s products and components are subject to extensive quality controls in an effort to provide the highest levels of comfort and well-being.

Why Pikolin chose our integrated solutions

Two businessmen are looking at each other. There are multiple screens with diagrams and data in the background.

Improving performance on all levels

Pikolin wanted to build a factory for the future, with cutting-edge technology that is expandable and flexible and that grows with the company’s requirements. This technology included a comprehensive and scalable SCADA solution for plant and process management.

Compliance with ISO 50001 / ISO 14001

Pikolin had a clear focus on designing environmentally friendly buildings, using the most advanced technologies available for the facilities. In line with this approach and to ensure compliance with ISO 50001 / ISO 14001, the company implemented a state-of-the-art energy management solution.

An exterior shot of a factory building, with “Pikolin” printed in red on the side of the building and trees in front of it.
A man, who is looking at a screen showing an application and data, is seen from behind.

Efficient engineering and maintenance

To be able to easily adapt both the SCADA system and the energy management system, Pikolin was looking for an integrated solution that also included the automation level. This would ensure that the systems could be efficiently engineered and maintained with the help of a local solution provider.

A very convenient solution for energy management

Since moving into its new facilities, Pikolin has significantly reduced the company’s energy consumption per square meter. This is due to the use of advanced technologies and the better control of the various energy sources that is enabled by SIMATIC WinCC and especially the analysis capabilities of SIMATIC Energy Manager PRO.

By using SIMATIC HMI operator interfaces, Pikolin has improved productivity, efficiency and usability. 30,000 data points, which can be accessed through 20 web clients, provide excellent data integration and visibility.

With SIMATIC WinCC and Energy Manager PRO, Pikolin can gather data from different sources together with detailed time information. This provides Pikolin with extensive analysis capabilities and control of its energy consumption.

SIMATIC Energy Manager is intuitive and easy to implement and operate, and it provides us with a powerful analysis and control tool.
Vidal Jose Beltrán Relancio, Technical and Maintenance Director, Pikolin S.L.

Well-equipped for future objectives

With a flexible and expandable energy management solution in place, Pikolin is well equipped for the next steps in its digitalization journey. New meters, data interfaces and optimization measures can be integrated as requirements evolve, creating a strong foundation for continuously improving energy efficiency, production and maintenance.