LED upgrade at Hampton Steel gives 52% cost saving

High-efficiency, low-glare Micro LED battens from Tamlite form part of a wider upgrade of a newly acquired building used by galvanised steel wire fencing specialist Hampton Steel. New lighting will pay for itself in two years.

Maintaining leading-edge production facilities has been integral to the company’s success, and it is in this context that it recently undertook a comprehensive upgrade of its new factory building in Wellingborough, Northamptonshire.

The change of location came in response to the company’s continued growth, but it did necessitate a thorough review of the new premises, which amongst other things featured an outdated electrical infrastructure. Lighting was another item high up on the priority list as the 700 old-style T12 batten fittings delivered very poor output throughout the high-ceilinged building.

A complete renewal of the lighting was essential before the new facility could be made operational. “The lighting needed to be extremely reliable over extended periods of operation, as well as offering a standard of illumination that was complementary to activity levels and the good health of our employees,” says Andy Hutchings, buyer at Hampton Steel. “Minimising the environmental impact and expense of our lighting installation was also crucial, and so after a period of market research we were led to Tamlite solutions, which it quickly became clear were able to tick all of the boxes.”

 

Next-generation LED battens

Tamlite has based the design around its Micro LED battens. A variety of capabilities recommended its specification for the Hampton Steel project, including efficiency of greater than 90 lm/W, a 50,000-hour lifespan, a cool-white light (400K) without glare, and an extruded aluminium body for efficient thermal control. The product also benefits from Tamlite’s work on bespoke optics in both narrow and wide beams – ensuring the light is directed precisely where it is needed.

I also realised that the long lifespan of LEDs could benefit the way in which we operate as a factory. Any light failure inevitably leads to the disruptive and time-consuming business of getting a cherry picker into position, as well as downtime in the affected area"

Andy Hutchings, Hampton Steel

The cost and energy saving calculations generated by Tamlite added further weight to the case. Based around a deployment of 350 fixtures, giving 400lux and 200lux light levels across the factory and warehouse areas respectively, the firm predicted that Hampton Steel could benefit from a 52% annual saving over the existing installation – effectively meaning that the new system would pay for itself in about two years. The upgrade was predicted to result in a reduction in yearly carbon emissions of 108425.9 kg.

Although Hutchings had nursed long-running concerns about LED technology “still being fairly new in terms of the overall history of industrial lighting”, these forecasts made for compelling reading. But what really made the difference in nudging him towards the Tamlite LED solution was the inclusion of a five-year warranty and guaranteed annual ‘health check’ visit for the first five years.

“Those elements certainly provided a welcome level of reassurance,” he confirms. “In addition, I also realised that the long lifespan of LEDs could benefit the way in which we operate as a factory. Any light failure inevitably leads to the disruptive and time-consuming business of getting a cherry picker into position, as well as downtime in the affected area. So that was another consideration that encouraged me to move ahead with an LED-based set-up.”

 

Quick supply and installation

Deployed in conjunction with occupancy sensors in the storage area to further optimise efficiency, the LED battens were supplied on a quick turnaround earlier this year. Implementation was speedy, with the product’s ‘Clip-n-Fix’ system, which facilitates a simple-to-fit installation with push-wire terminal connections.

It’s early days for the new lighting set-up, but the omens are looking good, says Hutchings: “The standard of the illumination is very good and has prompted a number of comments to that effect from our staff. The whole experience has been as pleasant and low-stress as possible as well –so it’s for all of these reasons that I subsequently enlisted Tamlite to provide new exterior and emergency lighting too.”

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