Monday, January 16, 2012

Case Study: Kimberly-Clark Cuts Energy Consumption 60% at Malaysian Facility

Kimberly-Clark Cuts Energy Consumption 60% at Malaysian Facility with Switch to Dialight DuroSite® LED High Bay Fixtures
Paper Mill Runs Greener, Cooler with Better Visibility for Workers and Inspectors

Installation Snapshot
• Two production floors
• Number of LED fittings – 114
• Replaced – 400W Metal Halide with 123W LED High Bay
• Energy saving – 60%
• Average w/m2 reduced from 12.49 to 4

With a global footprint spanning more than 150 countries, Kimberly-Clark’s Products have become a trusted part of life for some 1.3 billion people around the world. At its Family Care Production Facility, at Kluang, in Johor, Malaysia, the company manufactures a wide range of paper products including Kleenex facial tissues, and Scott paper towels, among others.

Aiming to reduce energy consumption and improve visibility within the plant, the company recently replaced 114 of its 400W metal halide lighting fixtures with Dialight’s DuroSite LED High Bays. Consuming just 123W, the Dialight High Bays have enabled the company to slash energy consumption and dramatically improve visibility, all while making the work environment more comfortable and safer for employees. The company has been so impressed with the results, it’s now considering an upgrade to Dialight fixtures at other areas within the mill premise.

Time for an Upgrade
When the Family Care Production Team began noticing low brightness on the manufacturing floor, the K-C engineering team set out to find newer technology to upgrade the existing lighting. One of the biggest contributing factors to the low quality of light, besides the rapid light depreciation natural to metal halide bulbs, was the degradation of the polycarbonate shields installed over each fixture. In the event a light bulb should burst in the overhead fixtures, the shields were designed to prevent a possible spark from igniting the tissue products on the manufacturing floor—a major safety concern. But over time, the shields had become faded and discolored, further reducing clarity under the metal halide lights. The shields were also prone to collecting insects, which further reduced effective light output on the shop floor. Poor visibility was especially an issue in the inspection areas, where low light conditions hindered the K-C Quality Assurance team’s efforts.

Furthermore, because of the region’s tropical climate, heat inside the facility was also a problem. The high-heat metal halide fixtures contributed significa ntly to this issue, which drove employees to switch off the lights to help keep the temperature down. But, with the long re-strike/warm-up times required for the lights to come back up to full output, this presented a significant safety concern.

Driven to Lead Sustainable Manufacturing Movement
In addition to visual acuity, the company also aimed to cut energy consumption. As one of the largest manufacturers in the world, K-C is committed to saving energy and optimizing efficiency worldwide—and serving as a leader in this movement throughout the Asia-Pacific region with its global Vision 2015 program. But, the Kluang facility’s current lighting efficacy was a paltry 12.49W per square meter (W/m2), mostly due to the fact that the lights were illuminating areas that were unnecessary, and they were often left burning when not needed to avoid the wait for restrike/warmup.

Dialight Outshines Local Competition
As the K-C team began evaluating options, they immediately looked to LED solutions, and even considered solar-powered products. Due to their location, they naturally evaluated products from local suppliers, including LED companies from Singapore and China. However, the North American-made Dialight High Bays offered better efficiency, shorter payback period and a longer lifespan backed by a full 5-year warranty, compared to just 2 years from the other suppliers.

The company’s global reputation and impressive list of customers were also determining factors. With the largest installed base of LED high bay fixtures in the world—more than 50,000 to date—Dialight’s experience gave K-C facility managers the confidence that product they’d chosen was already a trusted solution on a global scale.

The K-C team was also impressed with the 3D lighting simulation provided by Lumina Systems, the regional distributor of Dialight lighting products, which gave them a preview of the results before the fixtures were even ordered.

“With the lighting simulation, we could clearly see the optimum lighting layout for the space to be illuminated,” said Adam Lua Boon Chin, Project Engineer, Kimberly Clark Products. “We knew before installing that light would be directed exactly where we need it”

Energy, Maintenance Costs Shrink
With a 60 percent reduction in energy consumption, the K-C facility has been able to dramatically reduce its electricity costs. Now, lighting efficacy is at 4W/m2, less than a third of the wattage required with the metal halides units. And, because of the instant-on capability of the Dialight LEDs, K-C is also free to turn off the lights when they’re not needed, and can even strategically light only certain areas of the facility, such as alternating rows or only the perimeter, to save on energy use.

Because the Dialight products are expected to last up to a decade without ever needing a bulb change, K-C has also been able to reduce maintenance costs and demands at the facility. Changing bulbs in the existing metal halide fixtures not only interfered with production but also posed a safety hazard, as most of the lights were positioned above the manufacturing equipment. The Dialight fixtures virtually eliminate lighting maintenance, delivering improved quality of light while maintaining consistent light levels over their life.

And, since the lights themselves are fully enclosed and sealed to meet the HACCP and AIB food safety requirements, the risk of bursting bulbs is gone—as are the problematic spark shields. The lights are also much cooler, operating at less than 46°C, compared up to 232°C for the old metal halide units.

“Not only have the products performed exactly to our expectations, Dialight has provided us with thorough and professional support, which has also been very important for making this project a success,” said Chow Weng Leong, Engineering Manager at the facility.

Tuesday, January 3, 2012

Case Study: Olympus KeyMed Cuts Carbon and Lighting Costs with LED Solution

Installation Snapshot
• 3,380 square metres
• Number of fixtures – 100+
• Replaced – 400W metal halide
• Mounting height – 12 metres
• Energy reduction – 68%
• CO2 reduction – 85 tonnes per annum
• Watts/sqm reduced by 68%

UK-based at Southend-on-Sea and employing over 1,000 people, Olympus KeyMed is a wholly-owned subsidiary of Olympus Corporation, Japan. As such it is an important part of the global Olympus network, with specific responsibility for the development and manufacture of medical equipment and industrial products for distribution world-wide.

The lighting challenge
Olympus KeyMed’s Southend-on-Sea facility comprises warehousing and manufacturing with sheet metal as well as a paint shop. Here it not only produces medical and industrial products, but it is also the sole UK point of importation and distribution of all Olympus products. “Our target is to reduce CO2 emissions in the company by 50% by 2020 in both our buildings and our products,” explains Chris Owen, Olympus KeyMed’s Environmental & Improvement Engineer, “so that boosted our decision to change to a more energy efficient lighting solution. With over 100 metal halide high bay lights across our 3,380 square metre facility, we found that the 400W high bays were actually operating at 440W and accounting for 10% of our total energy usage.”

Chris also found that the metal halide high bays were lasting two years at best or 15,000 hours on average, though replacement cycles could be shorter as a result of heat generated and accumulation of dirt. Additionally there was the ongoing chore of inspecting for failed lights and servicing those that had failed.

The lighting solution
After researching the LED market, and with the recommendation of energy consultants Interior Control Ltd., Chris looked at LED technology specialist Dialight’s energy efficient lighting solutions. He was immediately attracted by their five-year continuous performance guarantee and very low wattage which would enable him to comfortably recoup all of his cost through energy savings made within the guarantee period.

“It’s a no-brainer,” he said, “as these lights will actually last much longer than the guarantee period; so as a real bonus we will have no maintenance chore, or cost, ever again – really excellent! It’s no wonder that the decision to purchase Dialight’s LED lighting flew past our executive committee. With Dialight’s 40 year LED experience and proven quality there was no other product which came close for price and durability.”

The outcome
Mounted at a height of 12 ms, the metal halide high bays were replaced one-for-one with Dialight DuroSite® 150W LED High Bays. Significantly this led to the discovery that the actual consumption of the LED High Bay lights including drivers was 5-10% less than the expected 150W – an additional energy saving bonus while maintaining the same light level but immediately reducing energy usage by over 68%. As a result, Olympus is now on target to cut carbon emissions by 85 tonnes per year.

In the manufacturing side of the business the lighting runs 24 hours/5.5 days a week, while in logistics it runs 14 hours/5 days a week and Chris Owen is already considering introducing PIRs/Lux sensor control in both to deliver further energy and carbon reductions. He is also working hard with Interior Control Ltd to install Dialight’s LEDs on the exterior of the building both in the car park and pathways, as with PIR control these can also have excellent pay back periods of less than 4 years.

Re-strike time had been an issue in all areas with the metal halide lights, especially in the inspection area, so low level fluorescents had been installed as back–up to avoid production downtime. With the instant-on ability of the LED High Bays these back-up lights can now be taken out. Chris is particularly pleased to note that the addition of some extra LED high bays in the inspection area has delivered a massive improvement and increased the lux level from 1,800 to a mighty 5,000.

About Interior Control Ltd
UK based Interior Control Ltd is an experienced professional team of engineers, designers, environmentalists and process improvement practitioners, providing energy metering and saving solutions that include LED lighting. They are proud to be an official agent for the Dialight range of industrial LED lighting products. More information about the company and their product range can be found at Carlton House, Gwash Way, Ryhall Road, Stamford, PE9 1XP. 01780 753316

Dialight LED High Bay Fixtures
Olympus Keymed Website