RPC M&H Plastics, Ellough lighting energy saving project with 74% energy and 690 tonnes CO2 saved.

RPC M&H Plastics, Ellough lighting energy saving project with 74% energy and 690 tonnes CO2 saved.

RPC M&H Plastics, has two sites near Beccles / Lowestoft, East Anglia. The site in Ellough has a mixed range of buildings: production halls running 24/7 to 9 m high and warehousing, stores and associated production offices. The lighting was a mixture of mainly metal halide, sodium and T8 fluorescent fittings. Lighting was at various heights ranging from office level to 9m and lighting levels required from low level open warehousing to high level and quality of light for quality control inspection, and some street lighting. There were opportunities for enhanced savings through use of PIR sensors, particularly in the warehouses. The site had been engaged in an  aggressive programme of improving efficiency in all aspects of its business and part of that has been a project for a step reduction in energy consumption. The site had sought lighting upgrade proposals from other companies over a numbers of years. We were chosen for our experience and expertise in re-designing for optimum use of light and specifically our ability to get the highest energy savings, using latest and most efficient LED components from, almost completely at this site Philips lighting, and at a highly competitive price. We are also very well known to RPC having now upgraded many of their large production facilities around the UK. We had previously installed all new lighting for a production facility refurbishment in early 2016, and in 2017 worked through the whole production operations and warehousing replacing nearly all the lighting with our exceptionally high quality and efficient LED lighting, and designing in use of PIR’s to optimum benefit in the warehouses. The project was completed in late 2017. 1100 lights were upgraded across the whole range of buildings with new fittings and our retrofit products. For consistency of appearance and maintenance sparing and cost efficiency in procurement the upgrades were based on two of our very popular and successful products: The HiPW platform of product and retrofit products. We used Philips Lighting components, which are of the highest industry quality, reliability, efficiency. The HiPW is a base product unit where we can specify light output varying from around 6000lm to 24000lm using increasing combinations of the same LED products. The approach makes the range hugely flexible which still achieving highest efficiencies of the order 170 lm/Watt system efficacy. Nearly all production and storage areas were upgraded with this platform product. The ReTRO fit product as used to upgrade T8 batten fittings in stores, where they were integral with conduiting in the ceiling, and some task lighting for the simplicity and economic benefit of the upgrade. With this product we re-build the unit with all new internal wiring and LED driver and robust, maintainable LED strips, so the technical lighting components of the product are as-new. The process of upgrade in this 24 /7 production facility went exceptionally smoothly with close co-ordination between our very experienced staff lighting upgrade installers and the site maintenance and production teams.