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Product Update: Lighting Retrofits At Saint-Gobain

Mon, 07/22/2013 - 3:01pm

Saint-Gobain Oberland Chooses Energy Efficient LED Lighting

This article first appeared in IMPO's July 2013 issue.

With more than 15,000 people working at 58 manufacturing sites worldwide, the Saint-Gobain brand Verallia is a worldwide leader, specializing in high quality glass containers for baby food and many other sectors of the food and beverage industry. When the time came to renovate a quality control and packing hall at its Neuburg  glass packaging plant in Germany, Verallia was looking for a more efficient lighting solution to replace its 250W HPS high bays that were actually drawing 300W.

Seventy percent of the glass packaging produced at the Verallia plant is from recycled glass. The melting process is in continual operation 24/7 and likewise the packaging process where the lights are installed, so a high degree of availability and reliability was required. The old HPS high bays needed replacement every 8,000 hours and this process involved the regular expense of bringing in a scissor lift and specialist maintenance personnel.

It was also essential that the new lighting solution would be robust enough to comply with the plant’s HACCP certification, which is very strict about food safety and the elimination of the risk of any foreign objects in products.

The Solution

Head of Electrical Maintenance, Matthias Maile, tested two alternative LED high bays for three months before choosing Dialight’s DuroSite® Series 150W LED High Bay on the basis of its robustness and price. The 150W High Bay lights offered a payback time of about three years. He also preferred the ease of installation, which can be achieved with a single cable, and proceeded to replace all 65 of the HPS fittings with dimmable LED high bays on a one-for-one basis.

The Result

The 150W LED high bays have immediately delivered a 50 percent reduction in energy needs and the same reduction in CO2 emissions. With the ability to dim the LED high bays, the energy savings will increase further as daylight hours extend with the approach of summer.

Thanks to Dialight’s 5-year continuous performance warranty, maintenance has been eliminated.  The previous light bulbs had to be changed after 8,000 hours—nearly each year. With the new LEDs’ expected lifespan of ten years, it’s likely that they will pay for themselves several times over during their lifetime.

Matthias Maile comments: “Our forklift drivers like the LED light—it’s now delivering up to 190-250 lux at floor level. This is the first German plant in the Verallia Group to have LEDs installed and I’ll be discussing this experience with the electricians from our other plants in Germany, as I’m already planning to replace all our lights with LEDs.”

For more information, visit www.dialight.com.


See also:

Southeast Packaging On The Green Fast Track

Pro Weld Reduces Welding, Painting Energy Costs

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