Installed high overhead and in large numbers. A total of 536 luminaires are installed in the ceiling ten metres above us. Spenncon's massive production halls require ample and precise lighting around the clock. However, lighting shouldn't be wasted. Lighting is about electricity consumption - and subsequently about resources and climate footprint. This was a critical factor in Spenncon's decision to modernise the company's lighting system. Glamox was chosen as a supplier.
Inside the expansive halls northwest of Hønefoss, 200 employees manufacture a wide variety of concrete products; beams, columns, balconies, walls, floors. Each day 30-40 trailer loads depart from here. Annually, Spenncon Hønefoss supplies products to the value of approx. NOK 500 million to its customers. The company operates on a three-shift basis except at weekends, and good, stable lighting around the clock is essential. The combined annual power consumption of the numerous large luminaires previously totaled no less than 1.4 GWh.
Now, however, the large luminaires with metal halogen lights – that cost NOK 400 each and required replacing about once a year – are history. Instead you will find 536 LED luminaires, more precisely Glamox i80, a solid and efficient industrial luminaire with a light intensity of 22,000 lumens.
"This is an important project for us. We aim to reduce our climate footprint, and raise the bar for the quality of working conditions. We also want to prove to our customers that we operate on the basis of sound environmental accounting. By upgrading the lighting system, we have a win-win solution," says Kjetil Gjerdalen, factory manager at Spenncon.
The new lights are also smart. They can communicate with each other. They are controlled by sensors that register movements on the plant floor, and they are switched on and off as required. If a luminaire is alerted to switch itself on, it communicates with the five nearest luminaires. If activity ceases in the hall, the lights will dim after ten minutes to 10 percent intensity. They switch off automatically after 30 minutes of inactivity. In addition, the light level can be determined manually via a tablet in combination with a radio transmitter.
"We have seen that we often require less lighting, perhaps only 40-60 percent of maximum output," says Geir Andersen, technical manager at Spenncon.
Reduces power consumption significantly
The low energy consumption of the LEDs, combined with the integrated dimming and control functions, has resulted in a dramatic reduction in Spenncon's power consumption. The previous 1.4 GWh has been reduced to 350 MWh - and that's before taking into consideration the full effect of the control and dimming functions. The company estimates that electricity consumption will be reduced by a massive 87 percent. Add to this the long working life of the LED luminaires (approximately 100,000 hours) and thus lower maintenance requirements, which contribute to Spenncon's ability to achieve annual savings of approximately NOK 1 million.
The total solution delivered by Glamox, with wireless control, also made it possible to make use of existing cables and lines at Spenncon. Thus, the installation work cost only half of what a more traditional system with a data cable would have cost.
This also involves a stimulating "bonus": Due to the intense focus on innovation in the new plant, it qualifies for funding from Enova, the Norwegian State enterprise that promotes efficient and renewable energy and climate solutions. One-third of Spenncon's investment of NOK 2.7 million is covered by funding from Enova.
- This has been very good. Investments in machinery are often what is prioritised in our sector, but we've now been able to think alternatively. The technical solutions offered by Glamox, and support from Enova, result in a short repayment period and a modern, climate-friendly plant," says Plant Manager Kjetil Gjerdalen.