Industrial warehouse lighting upgrade

Project Payback

Haigh's Chocolates Mile End facility undergoes a lighting retrofit that improves light quality and safety for their staff.

Savings

Energy: 63%

Project Overview

Haigh’s is one of the oldest family owned chocolate makers in Australia. They employ over 600 people and are committed to premium chocolate making.

Haigh’s Chocolates wanted to improve the quality of light and safety for their staff, whilst also reducing their energy footprint at their Mile End facility in South Australia. This facility is used to store finished goods and raw material before dispatch.

Inefficient lights can account for 50%+ of your total energy bill, in fact warehouses with no manufacturing equipment are likely to see the lighting account for almost all of the energy used.

Testimonial

‘Continual maintenance on metal halides can be expensive, this was one of the reasons we decided to upgrade our facility. Lighting not only creates a safer work environment but designing quality lighting around workspaces, can decrease injuries and increase productivity and employee satisfaction. We are delighted at the results’

David Elliott DC Manager Haigh’s Chocolates

Gallery

The Solution

Globebusters, a trusted lighting maintenance group and S.Davis Electrical Contractors determined that lighting levels were low for the tasks being performed. Inefficient 250W & 400W metal halides were installed often in the wrong locations, these lights produce 15 to 30% of input energy to waste heat which was not ideal in a climate control environment.

Using the Tauro Black LED high bay, Haigh’s Chocolates has been able to reduce their energy consumption by 63% and they been able to improve the quality of light and safety of their staff. The Tauro Black incorporates optics for use in aisle racking applications. This makes it easy to achieve quality vertical illumination which assists with accurate barcode scanning and safer fork truck operation.

Installed were:
- 66 Tauro Black (30W, 90W, 180W) linear high bays
- 2 Kascade LED low bays suspended above the packing work benches
- 6 Noctua 40W forward throwing floodlights on the exterior of the building
- 5 Skyline 30W panel were used in the offices and break out areas
- 7 Vico batten

More Project Details (click to reveal/hide)

Project scope

The Mile End facility is used to store finished goods and raw material. The factory consists of 5 main areas, the storage of seasonal and
outside lines (Christmas and wedding collection, Mothers Day, Gift Range etc) the storage of standard lines (boxed chocolates, chocolate
blocks and bars,artesian range etc), dry goods and packaging, holding and dispatch area and the office/break room.

Products used

AREA	EXISTING FITTING (W)	LOSSES (W)	QTY	EXISTING LOAD (kW)	ENLIGHTEN LIGHTING	PROPOSED LOAD (kW)	REDUCTION (kW)	SAVING
Seasonal & Outside lines	250	25	15	4.125	Tauro Black high bay 90W, Kascade 200W	1.77	2.36	57%
Dry Goods & Packaging	250	25	21	5.775	Tauro Black high bay 90W, Kascade 200W	2.11	3.67	63%
Holding Area	400	40	7	3.08	Tauro Black high bay 90W	1.44	1.64	53%
Standard Lines	250	25	15	4.125	Tauro Black high bay 90W	1.35	2.78	67%
Standard Lines Cage	72	12	5	0.42	Tauro Black high bay 90W	0.18	0.24	57%
Office & Break Room	72	12	6	0.504	Skyline Panel 30W	0.18	0.32	64%
North Exterior Wall	250	25	2	0.55	Noctua Floodlight 120W	0.24	0.31	56%
East Exterior Wall	250	25	4	1.1	Noctua Floodlight 120W	0.16	0.94	85%
Receiving Dock	250	25	5	1.375	Tauro Black high bay 90W	0.45	0.93	67%
West Exterior Wall	80	8	7	0.616	Vico Batten 18W	0.13	0.49	80%

enLighten’s Tauro Black linear high bay luminaire was used in the storage aisles where racking is found, this luminaire
has industry leading efficacy of 165 lm/w.

Using the Tauro Black LED high bay, Haigh’s Chocolates has been able to reduce their energy consumption providing financial
benefits to their business and improved lighting for staff. The Tauro Black incorporates optics for use in aisle racking applications.
This makes it easy to achieve quality vertical illumination which helps with accurate barcode scanning and safer fork truck operation.