Large Manufacturing Facility

Large Manufacturing Facility

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Site Facts

  • Large Manufacturing facility
  • Multiple work areas - different lighting needs
  • Manufacturing, Warehousing & Offices
  • Materials handling
  • 24/6 Operational Hours
  • 312 Days per year
  • Over 150 Members of Staff
  • 570 Luminaires
  • 756,004 kWhrs of electricity on Lighting P.A

The lighting issues on site...

  • Over 20% of the Lighting faulty
  • Nearly 90% of the Lighting units 15 years old +
  • High Failure rates
  • High Maintenance costs for Lamp/Ballast Replacement
  • Restricted Access to Lighting units due to Plant Machinery
  • Insufficient Light Levels with Poor Uniformity
  • Depreciated Light Lux levels from 20-150 lx
  • High Energy Usage
  • 756,004 kWhrs on Lighting per Annum
  • No Lighting Control

The Challenge...

  • Design and install an LED lighting system for the entire site
  • Work only at weekends so that production is not affected
  • Reduce the Lighting Energy Consumption by 50%
  • Minimize the maintenance requirements for years to come
  • Increase Light Levels with enhanced Lighting Uniformity
  • Introduce a Consistent Cool White Led colour spectrum
  • Utilize Day Light Harvesting in Main Production Area
  • 500+ lx in Clean Room
  • Photocells to all External Lighting
  • Increased current Lux Levels by 100-300 lx (area dependent)

The Result…

  • An LED lighting system for the manufacturing area of the site
  • 570 LED luminaires have been installed
  • Fast track project delivery in 4 weekends
  • Lighting Energy Consumption reduced by 62.30%
  • 470,998 kWhrs saved P.A – 2,354,990 kWhrs saved over 5 years
  • All products are a minimum L80 50,000 hrs compliant
  • Enhanced Lighting Uniformity
  • Lighting automation/control
  • Zonal Daylight Harvesting Detection in Main Manufacturing Areas
  • Photocells to all External Lighting
  • Increased Lux Levels (min 25%) both internally and externally

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