Canopy assembly floor at Beekman Canopies under LED high bay lighting

Case study · Industrial & manufacturing

Lighting fixed first, energy second and still 45% less

Client

Beekman Canopies

Location

South Africa

Division

LED Solutions

Executive summary

Beekman Canopies manufactures vehicle canopies and canvas products, work that involves fitting, finishing and inspection at close quarters. The brief was to improve the lighting, with energy saving as a requirement rather than the objective. The upgrade removed an estimated 56,196 kWh a year, about 45% of the lighting load, and released an estimated 20 kVA of maximum demand, paying back in an estimated 28 months.

56196kWh

Energy saved per year
(estimated)

44.6%

Reduction in lighting
energy (estimated)

28mo

Payback on the
retrofit (estimated)

58tCO₂e

Carbon avoided per
year (estimated)

20.0kVA

Maximum demand
released (estimated)

Figures are estimates derived from project close-out data and standard operating assumptions. They will vary with tariff, run hours and site conditions, and are indicative of this project rather than a guarantee of results on another site.

The project

What the site needed, and what we did

Canopy manufacture is detailed work. Fitting, trimming, finishing and final inspection all happen at arm's length on surfaces where a flaw is small and the consequence of missing it is a return. Lighting that is adequate for moving stock around is not adequate for that.

The commercial problem is that quality-driven lighting projects are hard to fund. There is no line on the electricity account labelled defects missed under poor light, so the business case has to be carried by the energy saving even when the energy saving is not the reason for doing the work.

That constrains the design. A specification written purely for illuminance would have cost more and saved less; one written purely for energy would have delivered a darker factory more cheaply.

The project was scoped as a general lighting improvement: raise the standard of light on the production areas, and take the energy reduction that current product delivers on the way through.

At an estimated 45%, the reduction is the most modest in our published set, and that is the honest signature of a quality-led brief. Where a project is designed to maximise savings, light levels are held flat and every watt of the efficacy gain is banked. Where the brief is to improve the lighting, part of that gain is spent on the floor instead. Beekman spent a meaningful share of it on the work being done.

The payback, at an estimated 28 months, reflects the same trade. It is a longer return than a savings-led conversion would have produced, and it buys a better factory.

Why it worked

What made the difference

The brief was quality, not kilowatt hours

Fitting and finishing work needs light at arm's length. The specification was written for that and the saving followed.

The modest percentage is the point

At an estimated 45%, part of the efficacy gain was spent on light levels rather than banked. A savings-led brief would show a bigger number and a darker factory.

Funded by the energy case anyway

There is no line on an electricity account for defects missed under poor light, so the saving still had to carry the approval.

Carried forward

What we would tell the next client

Say which kind of project it is at the briefing stage. Savings-led and quality-led conversions look identical on a fitting schedule and produce very different numbers, and a client who expected 70% and got 45% will read a successful project as a failure.

Supporting references

  1. [1]International Energy Agency, The next wave of LED lighting · https://www.iea.org/reports/the-next-wave-of-led-lighting
  2. [2]DFFE, Grid Emission Factors Report · https://www.dffe.gov.za
  3. [3]Eskom Data Portal · https://www.eskom.co.za/dataportal/

Got a site where the
lighting isn't earning its keep?

Tell us the areas, the hours they run, the lux you need to hit and your capex envelope. We'll come back inside the week with a design, a fitting schedule and a payback model.

Related: Industrial & manufacturing LED