September 2019

LED based lighting is an energy efficient technology that offers long life, low carbon emissions and high quality illumination Graeme Shaw, technical application manager at Zumtobel, explains why it’s time for industrial and manufacturing facilities to make the switch. The future is bright L ED technology has created a step change in lighting with a combination of increasingly innovative solutions and fast return on investment (ROI). So, given that ED lighting can save money and reduce carbon dioxide (CO2) emissions. By choosing a quality luminaire designed for use in the space and a functional lighting design, helps improve employee productivity and wellbeing, then why aren’t all owners and operators of industrial and manufacturing facilities upgrading to this technology? Time and effort The simple answer is that there remains a culture of just replacing defective technology, such as high intensity discharge sodium luminaires (SONs) and T12 fluorescent lamps, with the same inefficient products. While in isolation this might be a relatively quick, easy and low cost fix, it ignores longer-term operational expenditure concerns and leads to a ‘patchwork’ effect of inconsistent light. In addition, carrying out a point for point replacement, or redesign, of an existing lighting infrastructure is usually perceived as being costly, time consuming and, above all else, disruptive. Lighting industrial and manufacturing environments certainly poses some unique challenges. For example, a lighting specification within a facility may have been amended since its initial design, while the activities carried out within the space may now differ from the original purpose. Furthermore, access to existing lighting may be restrictive and production schedules could hinder any upgrade activity. Plan of action With the right planning and a phased implementation that is flexible and accounts for operational requirements, the process can be relatively straightforward. First of all, close discussion with shop-floor shift management and operatives is crucial to ensuring production is not compromised, with a clear programme of works defined. It is advisable to target any ‘low hanging fruit’ first and then rollout a strategy for more complex installations – such as those in high ceilings – based around work patterns. For Most industrial and manufacturing facilities are ‘always on’ and, as a result, energy use can be very high. According to the Carbon Trust, lighting typically consumes 20% of the electricity used in these buildings, so finding cost effective ways to reduce levels of electricity consumed by lighting can deliver appreciable savings. Recent advances in LED technology mean that, dependent on operational hours and existing lighting infrastructure, it can cut lighting costs by up to 80% each year and deliver an ROI in under five years, especially if the Enhanced Capitol Allowance (ECA) benefit is claimed. Storage areas often have high operational hours with relatively low occupancy. Therefore, lighting control is key in terms of lowering energy use, and presence detection and daylight control can improve savings by 20- 40%. LED luminaires can be integrated with sensors to control when and where lighting is used within a space. They can then monitor light levels and make use of daylight harvesting, 50 | Plant & Works Engineering www.pwemag.co.uk September 2019 Premises & Facilities Management SPECIAL FOCUS instance, if there is no work scheduled in a specific area, work can be carried out during this period of downtime. Continuing with the subject of avoiding disruption, the reliability and long lifetime of LED luminaires can also significantly reduce maintenance and replacement costs, so much so that they can almost be considered a ‘fit and forget’ solution. Studies show that LED light output remains steady at less than one per cent degradation per year over the life of the device, while fluorescent and high intensity discharge SON fixtures can require re-lamping in as little as every two years. Spend and save The cost of replacing a lighting infrastructure is often considered prohibitive and LED lighting still suffers from a reputation for being expensive. The truth is that prices have declined to a point where this type of lighting is becoming the economical choice in almost every application.