Energy Saving Lighting Case Study – Knauf Insulation St Helens Plant

Site Facts

Location

St Helens, Lancashire, UK

Facility

Large Manufacturing facility

Sector

Manufacturing, Warehouse & Offices

Lighting Needs

Multiple buildings – different lighting needs

Opening Hours

24/7

Days Open

365 days a year

Members of staff

Over 500

Luminaires

1,800 Luminaires

Electricity

2,868,175 kWhrs of electricity on Lighting P/

Energy Saving Lighting Case Study – Knauf Insulation St Helens Plant

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 20lux – 250 lux

  • High Energy Usage

  • 2,868,175 kWhrs on Lighting per Annum

  • No Lighting Control

The Challenge

  • Design and install an LED lighting system for the entire site

  • 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

  • Utilise Daylight Harvesting in Main Production Area

  • Presence Detection in Warehouses

  • Photocells to all External Lighting

  • Increased current Lux Levels by 100-400 Lux (area dependant)

Result

  • An LED lighting system for the entire site

  • 1,599 LED luminaries have been installed

  • Project duration 6 weeks

  • Lighting Energy Consumption reduced by 65.44%

  • 1,877,088kWhrs saved P.A – 9,385,440kWhrs saved over 5 years

  • All products are a minimum L80 50,000hrs compliant

  • Increase Light Levels with enhanced Lighting Uniformity

  • Lighting automation using presence and daylight harvesting

  • Zonal Presence Detection in Warehouses

  • Photocells to all External Lighting

  • Increased current Lux Levels internal and external