Project Description

The Brief

Saint-Gobain Glass was looking for a significant reduction in its electrical lighting costs, improved lighting and fast payback. Furthermore, we could not disrupt their workflow during the installation. The project was also made more challenging by the site conditions, where temperatures would reach 70°C, a very high temperature for LEDs to work in. Due to the size of the client, we carried out several site visits and surveys over a number of months. We sought to get a real understanding of the client, what they did and how they operated. We achieved this by spending a considerable amount of time on site, talking to staff and management to understand their processes. To ensure we delivered the best solution, several trials were undertaken, testing a variety of LEDs, from office lights to warehouse to external lighting.

Key Targets

  • Reduce energy usage
  • Improve light quality Payback of less than 2 years
  • No disruption to day-to-day operations of the workforce and machinery
  • LEDs that would work at extreme temperatures
  • Reduce maintenance costs

The Solution

Our first challenge was to design a bespoke LED light fitting that would allow the LED lights to operate in 70°C heat. Following considerable Research and Development time, we produced a solution that had a tolerance of 75°C.

Phase 1 comprised removing low-level T8 lights and replacing them with LED versions fitted with microwave sensors. This reduced energy consumption while maintaining safe working conditions as sensors trigger the lights before staff reach the work area. We also removed a large number of low bay lights and replaced then with our high power 100 and 150 watt SMD LED Low Bay lights, again fitted with microwave sensors. Installation was completed within agreed time frames and we worked to strict parameters set down by the client.

Following the successful completion of Phase 1, Saint-Gobain Glass has now placed orders for the second phase. This will involve installing our fully-tested bespoke high temperature LED lights, 27 Watt LED Grill Panels and anti-corrosive LED light fittings in offices, washrooms, welfare facilities and other working areas.

We are also now discussing Phase 3, which will almost complete the site’s full conversion to LED.

Results

Phase 1

  • Annual Energy Savings: £4,029

  • Annual Maintenance Savings: £3,348

  • Estimated Sensor Savings: £2,656

  • Payback Period: 1.5 years

  • Total Savings Over 10-Year Lifespace: £100,330

Phase 2

  • Annual Energy Savings: £11,642

  • Annual Maintenance Savings: £1,656

  • Estimated Sensor Savings: £3,224

  • Payback Period: 1.4 years

  • Total Savings Over 10-Year Lifespace: £165,220