Hydro Aluminium Extrusions lighting energy saving project with 72% energy and 1067 tonnes CO2 saved.

Hydro Aluminium Extrusions lighting energy saving project with 72% energy and 1067 tonnes CO2 saved.

Hydro Aluminium is a division of Norsk Hydro of Norway. Vita Energia secured a multi site contract to upgrade their production area lighting to LED. The sites have a mixed range of buildings: production areas running 24/7 and warehousing, stores and associated production offices. The sites are complex with just in time production in space efficient factories. Planning and co-ordination was critical for this project.

The lighting was a mixture of old Sodium, Metal halide and T8 fluorescent fittings.The old lighting levels were poor and required to be improved both for light level and quality.  There were opportunities for enhanced savings through use of PIR sensors, particularly in the work-in-progress storage areas. As a major user of energy, the sites are targeted with annual improvements which are becoming harder to achieve with each year.Lighting is the last significant identified saving.

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. Due to the difficult access much of the lighting upgrade uses our new fittings. Speed of installation was key to the project execution.

Whilst there is a wide range of lighting applications around the sites, it was decided to keep the number of type of fittings to the minimum. A total of 3 types of fittings were used with the lux output adjusted to optimise energy saving with our simple resistor change. If the Hydro operations wanted more or less lux, this could be adjusted on site.

The process of upgrade in these production facilities went smoothly with close co-ordination between our very experienced staff and the site maintenance and production teams. With the minimal shutdown opportunities provided by Hydro, the project was staged over 12months; with each site completed in approximately 3 months.