Energy Saving Lighting Case Study – Knauf Insulation St Helens Plant
Site Facts
St Helens, Lancashire, UK
Large Manufacturing facility
Manufacturing, Warehouse & Offices
Multiple buildings – different lighting needs
24/7
365 days a year
Over 500
1,800 Luminaires
2,868,175 kWhrs of electricity on Lighting P/

The Lighting Issues on Site
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Over 20% of the lighting faulty
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Nearly 90% of the Lighting units 15 years old +
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High Failure rates
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High Maintenance costs for Lamp/Ballast Replacement
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Restricted Access to Lighting units due to Plant Machinery
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Insufficient Light Levels with Poor Uniformity
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Depreciated Light Lux levels from 20lux – 250 lux
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High Energy Usage
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2,868,175 kWhrs on Lighting per Annum
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No Lighting Control
The Challenge
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Design and install an LED lighting system for the entire site
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Reduce the Lighting Energy Consumption by 50%
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Minimize the maintenance requirements for years to come
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Increase Light Levels with enhanced Lighting Uniformity
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Introduce a Consistent Cool White Led colour spectrum
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Utilise Daylight Harvesting in Main Production Area
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Presence Detection in Warehouses
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Photocells to all External Lighting
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Increased current Lux Levels by 100-400 Lux (area dependant)
Result
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An LED lighting system for the entire site
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1,599 LED luminaries have been installed
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Project duration 6 weeks
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Lighting Energy Consumption reduced by 65.44%
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1,877,088kWhrs saved P.A – 9,385,440kWhrs saved over 5 years
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All products are a minimum L80 50,000hrs compliant
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Increase Light Levels with enhanced Lighting Uniformity
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Lighting automation using presence and daylight harvesting
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Zonal Presence Detection in Warehouses
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Photocells to all External Lighting
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Increased current Lux Levels internal and external