Reducing energy consumption while improving working conditions is a priority for many manufacturing businesses. IGS Electrical was appointed to deliver a comprehensive LED lighting upgrade across multiple production, storage and dispatch areas within a large manufacturing facility, helping to reduce operating costs, lower the site’s carbon footprint and improve overall lighting performance.

Project Overview

The existing lighting installation consisted of a mixture of fluorescent fittings, metal halide high bays and SON lighting, all of which had become increasingly inefficient and costly to maintain.

Following a detailed survey and energy assessment, we designed a phased lighting upgrade that provided improved illumination whilst significantly reducing energy consumption and maintenance requirements. The projected energy savings provided a payback period of just over two years.

Scope of Works

The project included lighting upgrades across several operational areas of the factory.

Storage Area

The existing fluorescent fittings were replaced with twin 6 ft LED luminaires complete with integrated microwave occupancy sensors. Emergency lighting was upgraded at the same time to improve compliance and reduce future maintenance requirements.

Assembly Area

The existing low bay lighting was replaced with a modular busbar lighting system fitted with Powerlite LED low bay luminaires incorporating microwave sensors.

Using a busbar arrangement provides greater flexibility for the future, allowing lighting positions to be easily relocated should the production layout change without major electrical alterations.

Dispatch Area

The existing lighting was replaced with high-output Powerlite LED high bay fittings complete with microwave sensors. The new installation delivered significantly improved light levels using fewer fittings and substantially reduced energy consumption.

Manufacturing Area

High bay lighting serving the manufacturing area was upgraded using high-efficiency LED UFO luminaires selected with a narrower beam angle to suit the mounting height. Due to the steam generated by the manufacturing process, fittings with a higher IP rating were specified to provide improved protection and long-term reliability.

Packing Area

Existing recessed fluorescent CAT2 fittings were replaced with modern LED panel lights, providing improved light quality, reduced maintenance and lower energy consumption.

Press & Machine Shop

The existing 400 W metal halide high bay fittings were upgraded by removing the control gear and lamps before installing high-output 230 V LED corn lamps. This provided a cost-effective retrofit solution while dramatically reducing energy usage and extending maintenance intervals.

Working in a Live Manufacturing Environment

Much of the installation was carried out using a cherry picker within live production areas. Careful planning and coordination allowed the works to be completed safely around large industrial machinery while minimising disruption to the customer’s manufacturing operations.

The Result

The completed project transformed the lighting throughout the facility. Improved illumination, integrated occupancy sensing and modern LED technology significantly reduced electricity consumption and maintenance costs while creating a brighter, safer and more productive working environment.

The predicted energy savings delivered an estimated payback period of just over two years, providing an excellent long-term return on investment alongside a substantial reduction in the site’s carbon footprint.