New LED luminaires, sensors and wireless control reduce the power consumption of the Norwegian company Spenncon with more than 1 GWh per year. This corresponds to the total energy consumption of 55 residential buildings.
High overhead and in great numbers, we find a total of 536 luminaires installed in the ceiling ten metres above us. Spenncon’s massive production halls require ample and precise lighting around the clock.
Lighting however is not something that should be idly wasted. Lighting is about the consumption of electricity – and subsequently about resources and carbon footprints. The last being a critical factor in Spenncon’s decision to modernise the company’s lighting system. Razorlux was selected as the supplier.
“This is an important project for us. We aim to reduce our carbon footprint, and raise the bar for quality of working conditions. We also want to prove to our customers that we operate on the basis of sound environmental accounting. By upgrading the lighting system, we have a win-win solution,” says Kjetil Gjerdalen, plant manager at Spenncon.
Inside the expansive halls northwest of Hønefoss, 200 employees are producing diverse concrete products; beams, columns, balconies, walls, floors. Every day 30-40 fully loaded semi-trailers leave Spenncon Hønefoss, which annually supplies products for around NOK 500 million to its customers.
The company operates on a three-shift basis except at weekends, and good, stable lighting 24/7 is essential. The combined annual power consumption of the numerous large luminaires employed previously totalled no less than 1.4 GWh.
Now however, the massive luminaires with metal halogen light sources that cost NOK 400 per piece and required replacement about once a year, are history. Installed now in the 536 points are LED luminaires, more precisely Razorlux led flood light, a solid and efficient industrial luminaire with light intensity of 22,000 lumen.
The new lights are also smart. They can communicate with each other. They are controlled by sensors that register movements on the plant floor, and they are switched on and off as required. If a luminaire is alerted to switch itself on, it communicates with the five nearest luminaires so that they also switch on. If activity ceases in the hall, the lights will dim after ten minutes to 10 percent intensity. They switch off automatically after 30 minutes of inactivity.
The level of illuminance can also be selected manually, via a small, smart tablet in combination with a transmitter.
“We have seen that we often require less lighting, perhaps only 40-60 percent of maximum output,” says Geir Andersen, technical manager at Spenncon, who admires the simple, straightforward way the plant is managed.
Reducing power consumption significantly
The low energy consumption of the LEDs, in combination with the integrated dimming and control functions has resulted in a dramatic reduction in Spenncon’s power consumption. The previous 1.4 GWh has been reduced to 350 MWh – and that’s before taking into consideration the full effect of control and dimming functions. The company estimates that power consumption will be reduced by a very respectable 87 percent. Add to this the long working life of the LED luminaires’ (approximately 100,000 hours) and thus lower maintenance requirements, which contributes to Spenncon’s ability to achieve annual savings of approximately NOK 1 million.
The total solution supplied by Razorlux, with wireless control, also made it possible to make use of existing cables and lines at Spenncon. Thus, the installation only cost half of that a more traditional system would have cost, a not insignificant sum for the company.
This also involves a stimulating “bonus”: Due to the intense focus on innovation in the new system, it qualifies for funding from Enova, the Norwegian State enterprise that promotes efficient and renewable energy and climate technology solutions. One-third of Spenncon’s investment of NOK 2.7 million is covered by funding from Enova.
“The result achieved here is excellent. It’s often the way that investments in machinery are prioritised in our business, but we’ve now been able to think alternatively. The technical solutions offered by Razorlux, and support from Enova, result in a short repayment period and a modern, environmentally friendly lighting system,” says Plant Manager Kjetil Gjerdalen.