Low Energy Lighting Boost for Manufacturer


With UK manufacturers having to scrutinise every aspect of their process to remain competitive, one such company based in Holton Heath near Wareham has found a solution which is already making a big difference to the working environment for their staff and the cost of running their three factories.

Led-Zip Lighting in Bournemouth has just completed a low energy, LED lighting project for Norco who manufacture GRP Mouldings and Composite Structures. Not only has the project created a platform for substantial cost savings and a fast payback on their investment – it has also made dramatic improvements to their working environment.

Norco operate in the aerospace, defence communications and marine sectors, and today own all three of their factories located on the Holton Heath Business Park. Launching as a small family business back in 1985, the company quickly established itself as a valued supplier to local marine giant Sunseeker.  Now, some 30 years on, they are still proud to count Sunseeker as a customer.

Norco Procurement Manager, Andy Watkins: We have further strengthened the business by moving into other sectors, and a tour of our factories today will include anything from sections of a luxury yacht to large aircraft wings or an equine spa for highly valuable race horses.”

norcoNick Bainton, owner of Led-Zip Lighting:
“We were introduced to Norco through a local energy initiative called Green PEA. The initiative’s message is clear; we ensure no organisation pays more for their energy than they need to – and in turn we reduce their environmental footprint. Norco was a fantastic project to work on, and one where we have been able to make many improvements, and not only in the reduction of their energy spend.“

Norco invited Led-Zip Lighting to carry out a detailed survey of the entire company. This was a comprehensive process which included light levels at each factory, a review of the various different light fittings adopted over the years – and the required functions of all three facilities.

Despite the diverse and dated lighting fixtures across the offices and 3 factory units, LED-Zip Lighting were able to find an LED replacement for each one.  They were also able to keep the same number of light fittings and by not adding any new ones it also kept installation costs to a minimum.

Nick Bainton: “In each case we replaced high wattage fittings with low wattage LED alternatives, from panel lighting in the offices to low bay fittings in the factory, as well as different sized single and twin fluorescent tubes and high impact rated fittings to take into account health and safety. As an example, we replaced 400 watt metal halide low bay fittings with 200 watt LED units.  The result – light levels went up and lighting costs came down.”

Light levels are extremely important to the health and well-being of staff, who in a manufacturing environment may only see natural daylight during break times.  Levels are dictated in ‘lux’, a standardised unit of measurement of light intensity per square metre. In one factory alone Led-Zip Lighting increased lux levels from 300 to 1000, creating a lighting simulation to that of real daylight.

Simon Hart, Charlie Bainton, Nick Bainton, Elliot Kenney
Simon Hart, Charlie Bainton, Nick Bainton, Elliot Kenney at Led-Zip Lighting

Following the lighting review of one of the Norco buildings with a five year lighting cost last recorded of £54,094, the predicted LED lighting cost calculation came out at £22,508. This has created a saving of £31,585. The company investment in the factory was £15,214, which will result in a fast 28-month payback.

Norco – Andy Watkins:  As well as the obvious energy cost savings, we also factored in the fact that the LED light fittings won’t have to be constantly replaced like the traditional lights.  In a large, factory environment that means the added cost of maintenance and also the cost of equipment hire to work at height. This has been a successful project for Norco in terms of improving the workplace, lowering our bills and adding to our environmental credentials.”

www.led-zip.co.uk    01202 577 400   nick@led-zip.co.uk