CARLSBERG HAS cut energy consumption by light at its logistics centre by 50 per cent by swopping 600 luminaires at five warehouses to high efficiency LED – saving 650,000 kWh and 400 tons of CO2 emissions a year.
The centre, in the town of Høje Tåstrup in Denmark, has 180 employees working on shipments of 2,500 pallets of beer every day.
A higher concern of the beer giant was safety. There are extensive safety measures throughout the logistics centre that aim to protect employees from accidents.
Walking and driving zones are clearly marked, warning tape to mark the potentially dangerous places, and video resources - all aim to educate, inform and integrate safety at the forefront of their operations and propel a ‘zero accidents’ ambition.
Since the logistic centre is open around the clock, all year round, proper lighting matters a great deal for improved safety: A clear and homogenous lighting of work and circulation areas facilitates orientation and can help to reduce accidents.
Carlsberg was conscious of the outdated and inadequate lighting system that was serving the five large warehouses and the outside area before the lighting upgrade.
The current conventional low light in some parts of the warehouse interior as well as exterior sometimes made it hard to navigate and work top efficiently.
The ramifications on safety, productivity, and overall employee stimulus – especially for night shifts, were all too significant to ignore.
Not to mention, the problem of fluorescent tubes and metal halide lamps burning out during operational hours and not being replaced due to the disruptive downtime a replacement would entail.
In their efforts to improve productivity, an improvement of the lighting was the next natural step.
‘Not only would a switch from conventional lighting to LED lighting provide us with a 50 per cent saving on electricity costs and a large saving of CO2 emissions, but we also needed energy-efficient, flexible lighting solutions that were a better fit for our purpose,’ says Jesper Larsen, head of distribution at Carlsberg, told Lux.
A proposal for a lighting upgrade prepared by the electrical contractor Michael Hansson from Kvalitek outlined a plan that would improve the lighting quality significantly for the day, evening and night shift operations, thus satisfying Carlsberg’s demands for a more sustainable, efficient, productive logistics centre.
In the five large warehouses, the conventional luminaires, each fitted with three 58 W T8 fluorescent tubes, were replaced with Damp Proof 55 W / 4000K LED luminaires from Ledvance.
Besides their high efficiency of 115 lm/W, the luminaires were selected for their high luminous flux of 6,400 lumen, their neutral white colour temperature of 4000K and their ability to live up to all norms required at Carlsberg Logistic Center.
With a lifetime of 50.000 h (L70 / B50) the LED luminaires last about 2.5 times longer than the conventional types.
The conventional lighting burned out frequently in the outdoor and loading ramp areas. This is where powerful metal halide spotlights had to light the driving paths for the trucks when loading and unloading.
With the new effective LED lighting upgrade, it will be a very long time between replacements, since the new LED floodlights 200W have a lifetime that is about five times longer.
Additionally, employees benefit from the very homogenous and bright light of the new LED floodlights with a luminous flux of 20,000 lumen. The lights are also used to illuminate the facades of the buildings.
All the way through, Kvalitek has worked on improving the light system for increased energy savings, a higher quality of illumination and sustainability.
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