August 22, 2023

Commercial LED Lighting Case Study

McDevitt Uniroyal Global

Over 500 lights with LED lighting across a 250,000sqft manufacturing, warehousing and office site

In this latest commercial LED Lighting project, we have replaced over 500 lights with LED lighting across a 250,000sqft manufacturing, warehousing and office site.

The complete LED lighting replacement plan is projected to provide a 64% CO2 saving, in addition to huge reduction in energy use and energy running costs.

Our clients Uniroyal Global Limited manufacture vinyl-coated fabrics for automotive, recreational, industrial, healthcare and hospitality markets worldwide.

Their site in Earby Lancashire, contains manufacture, warehousing, office and distribution space with a wide range of lighting that has been in place or replaced over the last 30 years.

In this period of time, lighting units have become damaged and faulty. Floor space use has changed as machinery is replaced and production lines have moved, meaning the lighting is no longer suitably placed for machine operatives.

Lighting tones are different in many areas as bulbs and lighting strips are replaced at sporadic times. As a traditional manufacturing site with 12 – 15m high ceiling and light fittings, it is time consuming to replace old bulb and lighting strips (requiring cherry pickers or scaffolding). All of these elements create major safety implications for the health and well-being of machine operators and are cosmetically off-putting for workers and visitors.

Project Objectives for Commercial LED Lighting

Uniroyal tasked McDevitt-Electrical with 5 key objectives

  1. Identifying use case for each area, create eco-friendly lighting plan, forecasting financial savings and carbon footprint reduction.

  2. Design new electrical circuit that is capable of running new lighting system across entire site, in use 24 hours a day.

  3. Source, install and maintain cost efficient, environmentally friendly LED lighting including emergency lighting and occupancy sensors.

  4. Ensure all manufacturing and warehousing can continue without disruption throughout works.
  5. Provide on-call emergency cover for electrical machinery supervision and maintenance.

McDevitt Electrical Works Included:

Pre work planning

  • Gathering site plans and identifying each area of use including ceiling and floor plans of manufacture and production zones, inspection areas, warehouse and storage, workstations task lighting, office space, staff rest areas, visitors and public access areas to provide suitable lighting environments.
  • Building site plan of existing electrical provisions.
  • Provision for occupancy sensors. These are a cost-effective lighting systems that are only in use in occupied areas or timed.
  • Provision of emergency lighting plan.
  • Electrical design, drawings, considerations, and recommendations report submission for approval to commence works.
  • Sourcing of all materials.
  • Working at height considerations for all employees including required machinery and required licences to use machinery.
  • Identify and remove any other dangers such as asbestos across the site.
  • Ensure materials used satisfy working conditions, such as vapour proof lighting.
  • Enable client to maintain 24-hour production and daily working practices with as little disruption to staff routines as possible.
  • Demonstrate forecasting of savings in energy spend and efficiency.

 

Works Completed

Over a scheduled 12-week period we have:

  • Safely removed all existing lighting and end of life cabling into waste management control.
  • Replaced over 500 lighting units with cabling within manufacture and production zones, inspection areas, warehouse and storage, workstations task lighting, office space, staff rest areas, visitors and public access areas.
  • Utilised most suitable lighting units dependent on area e.g. high and low bays, vapour proof.
  • Provided lighting solutions that are PIR occupancy sensor controlled and built-in self test emergency fittings.
  • Re-wiring of electrical feeds for areas with change of use.
  • Provide 5 year guarantee on fittings

 

Post Works:

  • On-going maintenance as required.

Client Feedback:

Mark Heron, Operations Manger at Uniroyal Global Ltd commented “We were under no illusions the planning and works completed that had to be carried out over a 250,000 sqft working site, would have to be meticulous”

“Pete and the team and McDevitts-Electrical demonstrated their vast capabilities in undertaking these projects from their previous experience and we were right to have complete confidence in them completing this project.”

“As a business, it is our policy to continue to reduce emissions at source and will not be satisfied until we reach our target of ultra-low emissions”.

“This project has generated a 64% CO2 savings and is all part of our new greener version of the future”.

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