Berry bpi, part of Berry Global Inc a huge plastic packaging, injection moulding and films company, has a plastic sheeting production facility in Ardeer on the Firth of Clyde, SW Scotland. It is an integrated set of some 10 acres of buildings on a site around 16 acres.
The lighting was a mixture of mainly T5 and T8 fluorescent and a few metal halide flood light fittings. VESL was selected to upgrade virtually the whole site to LED. The site has an aggressive programme to further reduce energy consumption.
After competitive bidding Vita Energia Solutions were chosen for our experience and expertise, and specifically our ability to get the highest energy savings, using latest and most efficient and reliable LED components and at a highly competitive price. We are also very well known to Berry having now upgraded many of their large and smaller production facilities around the UK and our installation service is very well tuned to work in a continuous 24 hr 7 day per week production environment.
The project achieved a global Berry award for exceeding 1 million kWhrs energy saving per year.
The main products supplied were from our HiPW and IP65 ranges. We re-designed the lighting in all main areas taking particular note to light quality and level specifying light output varying from around 6000lm to 18000lm 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. We used Philips Lighting components, which are of the highest industry quality, reliability, efficiency. Nearly all production and storage areas were upgraded with these platform products. Externally we switched old metal halide and sodium units for LED.
Selectively we specified and installed lighting controls in low usage areas to enhance energy savings and lengthen the life of fittings.
In 3 month period we worked through upgrading 900 lights with a team of our own staff installers. We included installation of some integrated emergency lighting fittings.
The process of upgrade in this 24 /7 production facility went very smoothly with close co-ordination between our very experienced staff lighting upgrade installers and the site maintenance and production teams, including achieving specific vital upgrades in a necessarily short and very busy maintenance shutdown period.