Tuesday, October 9, 2012

Case Study: Waste and recycling facility cuts lighting energy needs by 68% using LEDS

Installation Snapshot
• 50% failure rate in existing metal halide fittings
• (24) 400W metal halides replaced by (24) 148W LED high bays
• 68% cut in energy needs
• Lux levels increased x3
• 1.3 year payback
• 33.1 tonnes CO2 reduction over lifetime of lamps

Hazardous recycling shed is now safer, cleaner, brighter for workers and more sustainable.

Oxigen Environmental manages the waste streams of 100,000 domestic, commercial and industrial customers in Ireland. The company prides itself on utilising sustainable solutions to maximise resource efficiency through recycling and energy regeneration.

Recognising that the existing lighting in the recycling shed was inadequate and a drain on resources, the company set out to find a more efficient lighting technology.

Visibility in the recycling shed was very poor, as no natural light entered the building and the metal halides installed could not provide a good level of light output. The metal halide bulbs were prone to rapid deterioration and discolouring, and out of the 24 fixtures installed 50% had failed. Debris from the machinery added to the harsh and dusty environment of the shed, reducing visibility further as the halides accumulated dirt.

Maintenance became a big issue, as the positioning of the heavy machinery and height of the shed meant that the metal halides were difficult to access and the failed bulbs could not be replaced easily. The combined effect caused the workers to rely on the headlamps from the loaders.

Operating 24/6, the metal halide fittings proved to be very costly for Oxigen. Consuming 400W per unit, this resulted in an annual power usage of 85,363kWh which was not only a huge cost in electricity, but also a huge output in CO2.

Working with Commercial Energy Solutions, a company specialising in energy reduction usage, the halides were replaced one-for-one with Dialight’s high efficiency LED High Bays. Consuming only 148W, the units reduced the energy consumption dramatically, saving 68% in energy costs annually. The LED fixtures have instant on/off capability allowing the lights to be used when required, saving unnecessary electricity consumption and preventing irritation as the lights do not flicker on re-strike.

The shed is now three times brighter with lux levels at 140+ and as a result the workers can see clearly without relying on the headlamps of the loaders. This has improved health and safety significantly and the productivity in the shed has increased.

Maintenance has also been eliminated within the shed, as the LED units are sealed, with a life expectancy of 100,000 hours and an unconditional 5-year warranty, so no bulb replacements are required. As Dialight’s LED fittings are shock and vibration resistant, they are perfect for the hazardous environment of the shed.

With a payback period of only 1.3 years, the LED units have proved to be the best lighting solution for Oxigen. The units have also reduced carbon emissions by 68% and Oxigen can expect energy cost savings of £91,051 and 33.1 tonnes reduction of CO2 emissions over the life of the LED fittings.

“The CES team worked with us through each stage of the project, from proposal right through to completion. They delivered a high quality, energy efficient lighting solution that delivers tangible savings whilst achieving greatly improved light quality and levels.” Aidan Doyle, Director of Operations, Oxigen.