Case Studies

Lighting and lighting control upgrade – Stage 1

The leading Australian manufacturer of cross-linked polyolefin foams and composites has been manufacturing products in Australia since the 1970s. They have a very well connected global network. They market both products and solutions, servicing Australia, India, the Asia Pacific and Middle East regions

Energy assessment

Adviance Energy was engaged to examine the Caringbah manufacturing facility in order to identify efficient methods to reduce energy and offset current and future price increases.

The facility consists of two manufacturing factories, a product warehouse and an office area.

Excluding actual manufacturing methods and the office area (refurbishment plans were underway), the remaining function of the facility was quite minimal. The main production line operates 24 hours per day 5 days per week, through three shifts. Associated areas only operate a single shift. As a result, large areas of the overall facility and amenities were left unoccupied but continued to consume energy with active lighting and other equipment.

The existing high-bay lighting had to be switched on at all times, as staff needed access to equipment and amenities through areas not used at night, but existing lighting could not be isolated. Metal halide lamps have a delayed ignition after isolation, meaning all lighting had to remain ‘ON’ for the function and safety of staff.

Technical solution

We proposed the installation of new induction lighting in conjunction with a lighting control system incorporating daylight harvesting and occupancy sensors.

The new lighting would provide instant savings of 37 percent and would allow further savings through the lighting control system, which would otherwise not be possible with the existing metal halide lighting technology. We estimated the lighting control system would provide an additional 30 percent saving.

We also estimated an Energy Saving Scheme rebate of $280 per fitting and a Return on Investment for the overall project of 9 months.

Implementation

Adviance Energy was commissioned to complete stage 1 of our proposal in warehouses C&D.

We supplied and installed 300w induction light fittings to replace the existing 400w metal halide fittings. Whilst undertaking this installation, we relocated a number of fittings to suit the current layout and function of space.

We then initiated the installation of the lighting control system. The two warehouses were divided into five zones based on the function and time of use of each space. This would maximise the efficiency of the system with only local lighting activated when required. The system works by isolating all lighting in warehouse C&D through the day when light levels exceed 400 lux. With the article lighting averaging 130 lux (80lx required minimum under AS:NZ 1680.2.4), under 500 lux the system initiates the zoned sensors plus five security lights providing mimiml lighting in essential areas. There is also a timer installed to isolate all lighting outside standard production times (weekends) and an after hour run down timer if production exceeds the standard working hours and additional lighting is required.

Results

With the installation of the new induction lighting there was an instant and highly visible improvement in the quality of the light throughout both warehouses. The relocation of lighting also eliminated dark areas. The average lux pre implementation was

82.2 lux, and post implementation was 142.2 lux, or a 73 percent increase.

The lighting control system also provided instant results with the isolation of the artificial lighting on a sunny day from 8:30am-4:30pm. The sensors have worked well with only zones directly required throgh shifts two and three, activating when required and on average for only 10-15mins and other zones not activating at all most evenings.

Fantastic results have been obtained by the installation of data loggers on selected lights in different zones. Overall there was an 87 percent saving from information provided on a week-to-week period.