Fast payback for Wincanton


A combination of Chalmor’s Brilliance light fittings and Autolux controllers is providing significant savings in energy and carbon emissions for Wincanton’s automated distribution centre in Corby. The payback on energy savings alone is calculated at less than two years, with additional maintenance savings from longer re-lamping cycles reducing the projected return on investment to an estimated 1.6 years.

Brilliance fittings have been used to replace the existing 190 x 400W SON (high pressure sodium) fittings, on a point for point basis, increasing lighting levels while reducing the installed electrical load. In parallel with this, Autolux controllers, linked to photocells and presence detectors, have been installed to enhance the control of the lighting.

“We receive significant amounts of natural daylight through the roof lights, so we can now dim the lighting to take advantage of this – something that couldn’t be done with the SON lighting,” explained the site’s engineering manager Nathan Goudie. ”We are also using presence detection so that if an aisle is not in use the lighting can be switched off completely.

“Of the various companies we spoke to, Chalmor not only offered the best solution with the fastest payback, they also worked closely with us to analyse lighting needs and design the optimum control solution,” he continued.

Brilliance fittings use highly efficient T5 linear fluorescent lamps, providing better colour rendering, higher lighting levels and a life of 30,000 hours, so that re-lamping schedules can be extended to three years or more.

“The improved colour rendering has generated very positive comments from warehouse staff, especially on the night shift, because it makes picking much easier. The fact that we’ve been able to improve working conditions, reduce our carbon footprint and save money is a clear indication of the effectiveness of Chalmor’s lighting solution,” Nathan Goudie added.

In selected areas, the Brilliance fittings have been fitted with 4 x 54W and 2 x 28W lamps which can be switched in a variety of combinations to vary light levels. For example, for low background lighting just the 2 x 28W lamps can be switched on, and these can also be dimmed to compensate for natural daylight.

In addition, the lamps are addressable through the Autolux controllers so that ‘lead and lag’ lamps can be alternated to ensure even burning hours for all lamps in each fitting.

Autolux is a highly flexible lighting controller that provides cost-effective control based on occupancy, light levels and timer controls. At Wincanton’s Corby depot it proved to be perfect for meeting the range of different configurations required to match the lighting control to the needs of each area of the facility.

Chalmor faced another challenge in lighting the canopy over the external loading bay area, where fittings will be subjected to low temperatures in winter. Evaluation of projected temperatures meant special low temperature lamps could be offered in addition to fittings that retained lamp heat. This enabled Chalmor to provide a solution that would be effective even in freezing conditions.