Ansell Lighting – Warehouse Facility

Following a review of the company’s internal operations, Ansell Lighting recently undertook a significant upgrade of the lighting installation within the warehouse, located near Warrington, Cheshire. As a crucial hub for storage and distribution operations, the warehouse previously utilised a lighting system which wasn’t meeting the business’s needs.

The proposed upgrade needed to meet several business goals, including achieving sustainability and flexibility, as well as increasing energy efficiency and lowering ongoing maintenance costs.

The previous system did not provide optimal visual comfort or performance for warehouse staff, and lacked flexibility, making it difficult to adjust the lighting based on the specific requirements of different aisles and tasks.

To address these challenges, the company implemented a comprehensive lighting upgrade, selecting both the Z LED Performance and Z LED Linear Opti-X ranges of luminaires.

Initially, the Ansell Lighting Design team were asked to provide a lighting solution, which, together with rendered images, was carefully planned and executed to minimise any disruption to warehouse operations. These designs ensured the correct placement of fittings, optimum light levels where required, and supported the electricians during installation.

The installation of both the Z LED Performance and Z LED Linear Opti-X luminaires in the warehouse, combined with their high energy efficiency, resulted in an immediate reduction in energy consumption.

The Z LED Linear Opti-X also provided significantly greater flexibility, as it is a multi-wattage fitting with an adjustable beam angle. This allowed the electrical contractors to install these fittings throughout the different racking aisles and adjust the beam angles accordingly. This meant that the lighting solution achieved a consistent look and feel throughout the warehouse.

The Z LED Performance is also a robust LED highbay, ideal for industrial applications. Its die-cast, powder-coated construction and heatsink provide optimum thermal performance, while offering flexibility in installation options through drop rods, jack chain, catenary wire, and brackets for ceiling or wall mounting.

Ingress protection is to IP65, and it is pre-wired with 3 metres of H05RN-F cable for ease and speed of installation. It is available in both 4000K and 6500K versions, with 1-10V dimming as standard, but with an OCTO Smart Control version available upon request. The fitting is also available with emergency lighting, a microwave sensor option, automatic 1-10V dimming with time delay, and pre-set dimming levels. Dimming can be adjusted via a dipswitch or remote control, with versatile sensor programming options such as hold time, stand-by dim level, and more. The fitting comes with a 110° beam distribution pattern, with additional lens options of mid (85°) and narrow (55°) beam angles, providing an ideal solution for racking aisles.

The Z LED Opti-X was chosen for its powerful and durable multi-wattage, multi-beam angle design. This IP65 linear high bay is ideally suited for the demands of numerous industrial applications, including production facilities and warehouses.

The system’s versatile installation options at various heights enable optimal functionality, with two switches allowing users to adjust the output to 100W, 150W, or 200W. It also offers four beam angle options (40° x 80°, 50° x 100°, 70° x 120°, and 100° x 120°) for adaptability in different applications. This is ideal for leased warehouses, as end-users can modify the installation to meet their needs without the need for electrical work.

Dimmable 0-10V and 1-10V options are fitted as standard, where the installer is required to drill through the pilot hole and use an IP-rated gland during installation. The fitting also offers a plug-and-play microwave sensor, allowing for maximum energy savings.

The die-cast aluminium construction provides thermal performance, enhancing LED lifespan, and is suitable for both suspended and surface mounting.

The additional incorporation of the self-test emergency option within fittings containing an emergency pack ensures compliance with routine functional and duration testing, in line with relevant emergency standards. This reduces the burden of manual maintenance by using automatic indicators, allowing for quick and accurate maintenance.

OCTO and OCTO Insight

Another key component of the lighting upgrade was the integration of the OCTO smart lighting system, which allows independent control and dimming of each luminaire within the warehouse, providing greater flexibility and efficiency.

With the OCTO system, Ansell can easily set different lighting levels for various aisles and work areas, depending on requirements, ensuring optimal illumination levels and minimising glare. The ability to individually dim each luminaire means the lighting can be optimally controlled to meet the specific needs of the warehouse, as well as achieving energy savings and operational efficiency.

Alongside the self-test functionality, OCTO Insight was introduced, giving staff the ability to interrogate and monitor fittings. Information on the functionality of the fittings provides predictive maintenance and insights into energy usage.

Data management and reporting from devices mean the site can benefit from actionable insights. By utilising the OCTO Insight dashboard, data from the fittings is collated and analysed to support a shift from passive monitoring to proactive building management. The intelligent monitoring system enables the operations team to ensure lights are operating where required, and that emergency lights are functional and in good health at all times.

The Results

The lighting upgrade at Ansell’s warehouse delivered remarkable results, including significant energy savings of over 9 tonnes of CO₂e each year, with the company achieving payback on its investment within two years.

In addition to the financial and environmental benefits, the new lighting system offered several operational advantages. The improved lighting conditions enhanced visual comfort, visual performance, and onsite safety for staff working in the warehouse. The integration of OCTO and OCTO Insight supports ongoing maintenance, while the self-test functionality of the emergency fittings simplified compliance with testing requirements.

OCTO Insight also provided a deep understanding of the lighting setup. We could track the total luminaires on-site, monitor real-time data on active units, and check connectivity to see if they’re reporting data or powered. We now receive alerts for light output failures and have access to information on burning hours, offering insights into daily, weekly, monthly, and yearly operational times.

In conclusion, the lighting upgrade within the Ansell warehouse is a testament to the effectiveness of advanced lighting solutions in enhancing operational efficiency and sustainability. The significant energy savings and reduced maintenance, combined with improved lighting conditions, highlight the value of investing in modern, flexible lighting systems.

By implementing the Z LED Performance and Z LED Opti-X luminaires with OCTO control and self-test emergency, the company has achieved substantial cost savings, as well as creating a safer and more efficient working environment for its employees. This project exemplifies Ansell Lighting’s commitment to excellence and sustainability in all aspects of its operations.