BLV STATURION® The story of success
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BLV STATURION®
Sports facility lighting in a class of its own!
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In the beginning there was glass …
… and we use only glass in our production that meets the highest standards.
Copyright BLV, 2015
In the beginning there was glass …
The quality of the quartz is checked by visual inspection. The purer the quartz glass is and the fewer bubbles it has, the better the ignition properties and service life of the finished lamp will be.
Copyright BLV, 2015
In the beginning there was glass …
We do not go to production until the dimensional accuracy and the OH (hydroxide) content of the quartz tubes meet our high quality standards.
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Attaching and preparing the bulb
Only perfect bulbs yield perfect lamps. This is why we produce our own bulbs.
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Kolben ansetzen Attaching and preparing the bulb
The dimensional accuracy is essential during attachment – even minute deviations would be carried forward throughout the entire production process.
Cleaning and attaching the pump tube
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The finished bulbs are cleaned by heating before the pump tube is attached manually.
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Crimping
Now the systems are crimped into the bulbs. This requires the utmost precision and we make no compromises!
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Crimping
The complete crimping line was designed and built by BLV. All replacement and wear and tear parts such as burners, press jaws, and bulb holders are produced locally. We invest in the highest quality, which ultimately ensures our global reputation.
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Inspection
After this step of production, 100% of the products are inspected visually for possible cracks in the quartz. Even the smallest cracks can expand due to thermal stress, which the STATURION® lamps in particular are exposed to. This must be avoided in any case.
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Purging wheel
In this process, argon gas is pumped into the lamps. The gas completely displaces the oxygen from inside the lamps. This is important because even tiniest amounts of oxygen can cause oxidation of the electrodes and lead to the loss of ignition properties.
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Super heater
The lamps are then placed in a super heater, where they are cleaned again at approximately 900 °C.
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Super heater
The high temperature is required to remove the superficial water film from the quartz. This is another step to achieve optimal ignition properties.
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Filling with Hg
The cleaned lamps are now filled with mercury. The quantity of mercury is decisive for the operating voltage of the lamps. In this process, calculations are in the milligram range.
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Filling with Hg
Absolute perfection is required: The mercury dispenser and the pump were specially produced by BLV. When calculating the optimal amount of mercury, BLV is in the unique position to benefit from many years of experience not only in lamp construction, but in machine construction as well.
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Purging
Oxygen molecules that collected in the upper part of the pump tube in the preceding step of production are suctioned off. Even the tiniest oxygen residues would have a dramatic impact on the lamp quality.
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Glove box
The lamps are now filled with the filling cocktail in the glove box. This cocktail is every company’s big secret as it contains the core competence for optimal lamp properties.
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Pumping/purging process
After filling, the lamps are flanged to the pumping stand and filled with a gas mixture. The quality of our STATURION® lamps results from the interaction of these three components, ensuring optimal ignition.
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Separation
Now the pump tubes are separated from the lamps. This manual task requires particular dexterity because no air may leak into the lamps.
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Separation
We employ only highly qualified technicians who are trained in this manual skill through our extensive internal training programs. This ensures that the high BLV quality standard is maintained.
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Lux testing
Then ALL lamps are lux tested. This inspection step ensures that they were correctly filled with discharge gas and no oxygen leaked in.
Burning in the lamps
Now all lamps are burned in for 15 minutes.
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This process guarantees that the lamp voltage is optimal.
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Coating
After burning in the lamps and trimming the external wire and quartz tube extending below the pinch seal, they are coated. In this process, a powder is applied to the ends of the chamber.
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Coating
Coating creates a reflector that ensures the heat balance of the lamp. This is essential for achieving the extremely high performance of the STATURION® lamps.
Intermediate inspection
Now it’s time for an extensive intermediate inspection: Random service life tests are conducted in our own laboratories for 100 hours.
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This ensures for the last time that all technical parameters such as luminous flux, colour temperature, and colour rendering comply with the highest standards.
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Attaching the wire
After the endurance test is passed, the wires are welded on and …
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Cementing the axis
… the bases are cemented to the lamp axis.
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Final inspection
In the final inspection, the lamps are subjected to a 100% visual inspection and are lux tested once again.
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Attaching the cable lug
As a final step, the cable lug is attached. This completes the production process.
Outgoing goods inspection
Before final packaging, a comprehensive outgoing goods inspection is conducted.
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This is the last step in our quality assurance process.
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Global sales
BLV ships to over 70 countries all around the world.
Global sales
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Our STATURION® lamps light up stadiums from South Africa to Russia and from Brunei to Ethiopia.
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BLV STATURION®
A success story MADE in GERMANY!
