When Scottish high-end alcohol label printing company, Spirit Label Solutions, moved into a new £5m warehouse, they asked local business Electrical Solutions to come up with a lighting scheme, and with the help of Luceco, they delivered the solution.

Starting from scratch in an empty warehouse, Luceco carried out a survey of the site to decide the best indoor, outdoor and emergency lighting for the space.

This warehouse had to double up as both a printing warehouse and an office space, so the lighting had to be suitable for both applications, as Chris Bryant, Group Managing Director of Electrical Solutions (Scotland) explained: “The brief we were given by our contractors, Advanced Building Contractors Ltd, was to supply a lighting scheme for a manufacturing space and a small office in the same warehouse. The client had limited knowledge of lighting, so working with Luceco we were able to recommend the appropriate lighting and fittings for the job.

“When we visited the site with Luceco, we carried out a survey and produced a lighting design to meet their requirements. One thing we knew we had to get right was the balance of natural lighting in the space. The warehouse featured big skylights, which in the day provided the best natural light that wasn’t too warm or cold. We needed to replicate the same natural light when it got darker as accurate colour rendering is essential for printing environments and so LED lighting was an ideal solution.”

LED lighting provides the perfect solution for industries that require the LG1 recommended Colour Rendering Index (CRI), as it has only a small oscillation in light output and eliminates the strobed effect often caused by traditional lamped luminaires.

Following the site survey and lighting design, Spirit Label Solutions chose to use Luceco’s Elara Bay, cost-effective LED luminaires ideal for high ceiling mounting positions in industrial and warehouse environments, and surface mounted LuxPanels for the office spaces.

Chris said, “We chose to work with Luceco as we trusted them with their proposal and knew we were going to have their support throughout the entire project from planning and ordering to fitting and future repairs, and the client was delighted with the transformation.”

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Integral LED recently moved to a new warehouse in Calverton, Nottingham to meet the needs of their expanding operations.

The facility was in need of a full lighting refurbishment and improved efficacy and longevity were a paramount concern.

Challenges and considerations

There were multiple challenges to overcome in finding suitable lighting solutions for the new scheme. Luminaires needed to be carefully selected to accommodate narrow racking aisles and multiple functional areas, thoughtfully curated to reduce glare and wasted light at high levels. All lighting needed to be hard-wearing and reliable reducing maintenance whilst significant thought was also given to control options and sensors to enhance efficiencies.

Optimising lighting

Within the general lighting scheme, a range of new highly efficient high bays luminaires was chosen for installation within the warehouse racking area and above the mezzanine. Chosen for its high IK10 impact resistance, in-built Zhaga 18 plug & play socket and models with differing lengths and beam angles, the Integral LED Vector Max Linear High Bay offers an exceptional efficacy of 180lm/W for its compact size.

0.6m 150W Vector Max luminaires were installed throughout the internal aisles whilst for the outer perimeter and the mezzanine level 0.3m 80W luminaires were installed, taking advantage of the upper level windows and available natural light. All Vector Max luminaires installed featured an asymmetrical 30×70° beam angle, perfect for the spaces between warehouse racking.

Under the mezzanine level, rugged IP65 and IK08 4ft long Integral LED Vapourlite Non-Corrosive battens were chosen, offering power and CCT switching capabilities adjustable to suit the needs of the installation.

Motion sensors were also crucial to creating an efficient lighting scheme with both Microwave and PIR (Passive Infrared) options tested. PIR sensors were chosen for high-traffic areas such as goods in and packing and the perimeter areas of the warehouse floor, whilst Microwave sensors provided good detection in the central aisles and ensured lighting was available when required.

A separate emergency lighting scheme, using Integral LED 1500lm Self-Test Emergency Bulkhead luminaires, was installed to ensure regulation compliance and safe egress from the building. This is being covered by a stand-alone case study and excluded from the ROI calculations of the lighting scheme.

The results

During the renovation, all luminaires were switched from fluorescent to LED.

The previous installation consisted of:

• –  170x 5ft 4 lamp fluorescent high bays (80W lamps)
• –  64x 4ft twin lamp fluorescent battens (36W lamps)

The new installation consisted of:

• –  82x 0.3m Vector Max High Bay
• –  88x 0.6m Vector Max High Bay
• –  64x 4ft Vapourlite Battens

In doing so Integral LED managed to save a whopping £28,477.18 on energy costs per annum and will see a return on investment in 4 months. The switch also allowed Integral LED to save 81,363kWh of electricity and 21,561kg of carbon emissions every year.

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The column where you get to put your lighting questions to the head of the Ovia lighting business, Mike Collins, and his team of technical experts.

Q. WHICH LIGHTING PRODUCTS WOULD YOU RECOMMEND FOR A WAREHOUSE AND WHY?

We’ve recently reviewed and upgraded the warehouse lighting at another of the Scolmore Group companies, ESP, to replace old incandescent light fittings with much more energy efficient LED alternatives.

In general, we would recommend the Ovia Inceptor Hi-Lite LED dimmable Highbay luminaire with microwave sensor. There are various considerations to take into account when selecting a microwave sensor, such as the size of the space, and potential triggers such as ventilation fans, vibrations and water pipes. The parameters of the sensor can be changed to accommodate different applications and to eliminate any false triggering.

The Hi-Lite highbays are CCT switchable in 4000K, 5000K and 6500K, and come in black as standard and in a choice of wattages – 100, 150 or 200 W. They can be wall mounted or suspended which makes them very versatile. The luminaire can be mounted up to 12 m in height with a detection range of up to 15 m, while a chain mounted hook is supplied as standard.

The Hi-Lites can also be set to turn off immediately after an area is vacated or set to a secondary level for security purposes for a set time.

Whether you’re starting from scratch with a new build or you’re retrofitting an existing warehouse and lighting system, Ovia offers a free design service with a team of lighting experts on hand. They provide expertise in selecting the right products and solutions to create a scheme that meets all requirements and objectives of the project and is compliant with all the relevant regulations and standards.

Put your question to the Ask Ovia team here

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LEDVANCE is showcasing a range of lighting solutions to satisfy the unique requirements of production and storage facilities.

The requirements for a lighting system in a storage environment are diverse and a flexible system that can be easily adapted to changes in working processes is essential. The TruSys FLEX DALI system is an ideal lighting control for an entire building that can manage over 1,000 individually addressed luminaires across rooms and floors, operated by simply using a pushbutton or app for smartphones/tablets.

A typical high-bay warehouse is characterised by high ceilings, narrow aisles and hardly any natural daylight. In addition, the large difference in brightness between indoor and outdoor areas produces a high risk of accidents in entrances and exits. Even from an exceptional ceiling height of nine metres, the LEDVANCE High Bay DALI LED luminaires provide uniformly good illumination, and the daylight control of the DALI-2 drivers enables additional potential for energy savings.

In a production environment, the demands for a lighting system are varied: from rough manual work to fine assembly activities and visual inspections. The LEDVANCE DAMP PROOF Gen 2 DALI meets all these requirements with its high protection against shock, dust and water.

Loading areas are often particularly busy at night. With large trucks manoeuvring and goods being loaded and unloaded, the area quickly becomes crowded and difficult to keep track of. This makes lighting that provides orientation and safety all the more important. The LEDVANCE FLOODLIGHT performance is ideal for loading zones, as well as for facade illumination and lighting close to buildings.

For facilities looking to retrofit LED lamps into an existing lighting solution, the LEDVANCE LED Tube range is an ideal first step. A stand-out product for production and storage environments is the LED Tube T8EM PRO, which has a full-glass portfolio to protect against bending and a shatterproof protection sheet.

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