Tuesday, February 26, 2013

LANXESS Chooses Dialight LED Lighting for New State-of-the-Art Facility in Jurong Island, Singapore


Installation snapshot
• 200,000 sqm new facility
• 2,370 LED lighting fixtures for indoor /outdoor process areas and internal roads
• 55% energy reduction
• Annual power savings 1,150,000kWh / SGD 241,500
• 811 metric tonnes CO2 emissions avoided annually
• ROI in 1.5 years for 24 hours operated fixtures
• ROI in 3 years for 12 hours operated fixtures
• Maintenance reduced

New best in class facility is more energy efficient and environmentally friendly with the adoption of LED technology

LANXESS, a leading specialty chemicals company, announced the construction of a new butyl rubber plant in February 2008, to be located on Jurong Island, Singapore. Sitting on a 200,000 square metre plot of land, the new facility will process 100,000 tons per annum and LANXESS has allocated a record amount of EUR 400 million for this investment.

LANXESS carried out a complete evaluation of the existing process to manufacture butyl for the new Singapore facility and a radical redesign was implemented. The process, which draws on LANXESS long history of rubber expertise, will be best in class. A state-of-the-art power management and monitoring system will be installed.

The Challenge
LANXESS’s key objectives for the butyl plant are to be more energy and resource efficient, and also more environmentally friendly. The LANXESS project team recognised at the outset that the lighting solution would play an important role in achieving these objectives.

The challenge was to find suitable light fixtures that were certified for use in the hazardous environment, would deliver reliable lighting in normal and emergency mode operation, and would meet the requirements for reduced energy consumption and reduced maintenance.

In addition the lighting had to meet the Singapore Standard SS 531 which recommends lux levels for different areas within a facility, and the Green Mark requirements in SS 530 which define the power consumption per square metre that must be achieved in order to be considered energy efficient.

During the detailed engineering phase Johannes Goertz who is the LANXESS PCT Project Manager also highlighted their special requirements for emergency lighting. Dialight was able to modify the design of the LED lighting fixtures with built in battery backup to meet LANXESS requirements.

The Solution
The original design for the facility featured a mix of fluorescent T8s and metal halide fixtures, but in 2010 LANXESS gave Dialight the opportunity to propose a new lighting design featuring its LED lighting technology and the benefits immediately became apparent.

Dialight provided the lighting design to convert the conventional lighting for indoors and outdoors areas to LED products for both non-hazardous and hazardous application, where LANXESS was able to save a significant amount of energy while complying with the SS 531 and SS 530 specifications. The decision to use LED lighting throughout the five major production areas of the facility was made simple with the 5-year performance warranty from Dialight which would result in eliminating the burden of maintenance.

The Result
By converting to LED lighting, LANXESS saw its energy consumption and carbon emissions reduced by 55%. The low operating temperature of the LED fixtures was also a health and safety benefit, as it removed the risk of burn injury common with metal halides for anyone who might come into contact with the fixture.

In Singapore the Dialight LED benefit of built-in surge protection is also an important advantage during the rainy season from October to December. The region is prone to lightning strikes which can cause surges, resulting in the burnout of unprotected fluorescent ballasts and the consequential expense of maintenance.

Monday, February 25, 2013

Dialight Announces Next Generation 20-Year Power Supply for LED Lighting Fixtures

New solid state power supply marks significant technological advancement for the lighting industry with two times the expected life of designs available today

Farmingdale, NJ (February 25th, 2013) – Dialight (LSE: DIA.L), the innovative global leader in LED lighting technology, today announced its innovation program has developed an industry leading solid state power supply with an expected life of 20 years. Dialight’s new power supply technology guarantees long-life performance even in the most demanding applications.

“Dialight has once again set the bar with our latest power supply design, providing our customers with reliable and efficient illumination for up to two decades in the harshest environments around the world,” said Roy Burton, Dialight’s Group Chief Executive. “Unexpected lighting failures and frequent bulb changes will become a thing of the past.”

The new power supply will debut on the company’s award winning LED High Bay products for industrial and hazardous locations in Q2-2013 and will be integrated into additional Dialight fixture families this year.

Superior Innovation
Dialight’s in-house power supply development has already proven to be a significant benefit for its customers resulting in LED lighting fixtures with superior lumen-per-Watt efficiency, high power factor, low THD, various input supply options and high transient surge protection. With full quality control over every component within the electronic system, Dialight’s designs are based on topologies and design techniques developed over several years.

Efficiency and Lifetime
With a power supply efficiency increase of 7% from previous designs, Dialight’s new 20-year power supply will initially improve fixture lumen-per-Watt efficiency to over 110 lm/W surpassing competing LED fixtures and traditional lighting technologies alike.

Compared to conventional HID lighting fixtures with bulbs that last 2 years between changes and which often fail unexpectedly due to extreme temperatures and shock or vibration, the new Dialight 20-year power supply will offer a tremendous total cost of ownership savings. Maintenance can be very costly to replace these lamps in hazardous environments. Bulb changes require permitting, scaffolding to be erected, processes to be shut down and multiple personnel for safety supervision,

In many cases providing payback in less than 2 years, Dialight’s customers will continue to benefit from this new 20-year power supply design far into the future.

This new solid state power supply design is the latest innovation in Dialight’s rapid technology development program that has turned out a number of first-to-market technologies, including the first UL Class I, Div. 2 hazardous location certified high output LED fixture to achieve an efficiency of over 100 lumens per watt.

For more information about Dialight’s complete line of LED lighting solutions-including IES files, LM79 reports and technical datasheets—visit www.dialight.com. Dialight’s products are listed on the U.S. federal government’s GSA Schedule 56, contract number GS-07F-0664X.

Thursday, February 21, 2013

Saint-Gobain Oberland chooses energy efficient LED lighting for plant renovation


Installation Snapshot
• 65x250W HPS high bays operating at 300W
• Replaced one-for-one with 150W LED high bays
• 50% immediate reduction in energy needs and CO2 emissions
• Further savings when dimming comes into use
• Lux increased from 100-150 to 190-250 at floor level
• 5 year warranty = no more maintenance required

The Challenge
With more than 15,000 people working at 58 manufacturing sites worldwide, the Saint-Gobain brand Verallia is a worldwide leader, specializing in high quality glass containers for baby food and many other sectors of the food and beverage industry. When the time came to renovate a quality control and packing hall at its Neuburg glass packaging plant in Germany, Verallia was looking for a more efficient lighting solution to replace its 250W HPS high bays that were actually drawing 300W.

Seventy per cent of the glass packaging produced here is from recycled glass. The melting process is in continual operation 24/7 and likewise the packaging process where the lights are installed, so a high degree of availability and reliability is required. The old HPS high bays needed replacement every 8000 hours and this process involved the regular expense of bringing in a scissor lift and specialist maintenance personnel.

It was also essential that the new lighting solution would be robust enough to comply with the plant’s HACCP certification which is very strict about food safety and the elimination of the risk of any foreign objects in products.

The Solution
Head of Electrical Maintenance, Matthias Maile, tested two alternative LED high bays for three months before choosing Dialight’s DuroSite® Series 150W LED High Bay on the basis of its robustness and price. He also preferred its ease of installation, which can be achieved with a single cable, and proceeded to replace all 65 of the HPS fittings with dimmable LED high bays on a one-for-one basis.

The Result
The 150W LED high bays have immediately delivered a 50% reduction in energy needs and the same reduction in CO2 emissions. With the ability to dim the LED high bays, the energy savings will increase further as daylight hours extend with the approach of summer.

Thanks to Dialight’s 5-year continuous performance warranty, maintenance has been eliminated. With this and the LEDs’ expected lifespan of ten years, it’s likely that they will pay for themselves several times over during their lifetime. Matthias Maile comments: “Our forklift drivers like the LED light - it’s now delivering up to 190-250 lux at floor level. This is the first German plant in the Verallia Group to have LEDs installed and I’ll be discussing this experience with the electricians from our other plants in Germany, as I’m already planning to replace all our lights with LEDs.”

Friday, February 15, 2013