Playmobil Malta Ltd, a major manufacturing hub for the iconic German toy company, has been producing toys in Malta for over 50 years, with over 2.8 billion figures made between 1976 and 2015. The Malta facility is central to the company’s global operations and serves as one of the island’s largest employers, relying on cutting-edge manufacturing processes. 

To maintain the optimal environment for its operations, Playmobil Malta required a number of temperature sensors to be installed at various locations throughout its facility. The challenge was that many of these locations were inaccessible for traditional wired solutions. In addition, the temperature sensors needed to integrate with the plant’s existing Building Management System (BMS) play a critical role in the control loop for the site’s Air Handling Units (AHUs). 

To meet Playmobil’s specific requirements, Sontay in partnership with Engineering for Scient and Industry (Malta) Ltd, deployed a wireless solution featuring four indoor temperature sensors paired with a LoRaWAN (Long Range Wide Area Network) gateway. This solution enabled Playmobil to monitor temperatures effectively without the need for laying cables, which would have been complex and costly.

The LoRaWAN technology was chosen for its ability to provide reliable, long-range, and low-powered communication using CHIRP Spread Spectrum technology. With an outdoor communication range in excess of 10 kilometres, the system ensures consistent and uninterrupted data transmission, even from the most remote parts of the facility. 

One of the major advantages of Sontay’s LoRaWAN gateway is its easy-to-use control panel, which allows seamless connection to any existing BMS. This feature was critical for integrating the new temperature sensors into Playmobil Malta’s existing infrastructure without disrupting operations or requiring extensive modifications. 

The installation has produced positive results, providing Playmobil with the accurate and reliable temperature monitoring required to optimise its Air Handling Units and maintain the necessary environmental conditions for production. Furthermore, the energy efficiency of the system has been demonstrated by the fact that the batteries in the temperature sensors still show 100% charge after nine months of use. 

By using Sontay’s LoRaWAN gateway, Playmobil has benefitted from a solution that is not only highly reliable and scalable but also cost-effective in terms of installation and energy consumption. This project highlights Sontay’s ability to deliver advanced wireless solutions that support the critical operational needs of a world-class manufacturing facility.