Project Overview
Background
This project focused on revolutionizing the lighting system of a large industrial workshop facility in Brazil. The client was operating with traditional 400W HID lamps that were inefficient and underperforming. Seeking a solution that would exceed expectations in both performance and efficiency, the factory owner partnered with Gillson Lights to transform their industrial lighting infrastructure.
Core Objectives
- Performance Enhancement: Deliver superior illumination compared to existing 400W HID lamp system
- Energy Efficiency: Achieve significant reduction in electricity consumption and operational costs
- Safety Improvement: Create safer working conditions through even light distribution and elimination of shadows
- Productivity Boost: Improve visibility to reduce errors and accidents, enhancing worker efficiency
- Cost Optimization: Lower energy bills and maintenance expenses through LED technology
- Sustainability: Reduce carbon footprint supporting environmental responsibility
Technical & Installation Details
Design Highlights
- Industrial-Grade Construction: Specifically engineered for demanding factory and warehouse environments
- High-Ceiling Optimization: Designed to deliver effective illumination in spaces with elevated mounting heights
- Large-Scale Coverage: 340-unit deployment ensures comprehensive lighting across entire facility
- Proven Performance: Superior results compared to traditional HID lighting technology
Technical Parameters
- Power Efficiency: 120W LED replaces 400W HID—70% power reduction per fixture
- Light Output: 13,200 lumens per unit providing industrial-strength illumination
- Ground Illuminance: 250 lux achieved, exceeding client expectations
- Performance Comparison: 10% superior illumination versus previous 400W HID system
- Energy Savings: Over 30% reduction in total electricity consumption
- Total System Power: 40,800W LED vs. 136,000W HID (previous system)—95,200W savings
- Coverage Capability: Designed for large open spaces typical of factories and warehouses
Installation Advantages
- Comprehensive Assessment: Initial testing phase allowed client to verify performance before full deployment
- Customized Recommendation: 340-unit specification tailored to specific workshop dimensions and lighting requirements
- Proven Reliability: Product recommendation based on successful testing and performance validation
- Seamless Transition: Complete replacement of existing HID system with minimal operational disruption
- Ongoing Support: Continuous performance monitoring and client support post-installation
Application Areas
The 340 units of Gillson 120W LED High Bay Lights were strategically installed throughout the industrial facility:
Factory Floor
Primary illumination for main production areas where manufacturing processes occur, ensuring optimal visibility for precision work, quality control, and safe equipment operation.
Workshop Areas
Task lighting for technical work zones where detailed assembly, maintenance, and fabrication activities require clear, consistent illumination for accuracy and safety.
Warehouse Spaces
Comprehensive coverage for storage and logistics areas where inventory management, material handling, and forklift operations demand reliable high-intensity lighting.
High-Ceiling Areas
Strategic placement in spaces with elevated mounting heights typical of industrial facilities, where powerful luminous flux is essential for ground-level visibility.
Production Lines
Continuous illumination along manufacturing corridors and assembly lines where consistent lighting supports productivity and reduces worker fatigue.
Material Handling Zones
Safety-critical lighting in areas where heavy machinery operates, loading/unloading occurs, and workers navigate between workstations.
Project Benefits
Immediate Improvements
Superior Illumination Performance
- 250 lux ground-level illuminance exceeded client expectations
- 10% better lighting quality compared to previous 400W HID system
- Brighter, more uniform light distribution throughout facility
- Immediate enhancement of visual working conditions
Dramatic Energy Reduction
- Over 30% energy savings achieved from day one
- 70% power reduction per fixture (120W vs. 400W)
- Estimated 95,200W total system power savings across 340 units
- Immediate reduction in monthly electricity bills
Enhanced Workplace Safety
- Even light distribution eliminates shadows and blind spots
- Reduced risk of accidents and workplace injuries
- Better visibility for equipment operation and navigation
- Improved hazard identification in high-activity zones
Increased Worker Productivity
- Improved lighting enables more efficient task performance
- Reduced eye strain and worker fatigue
- Lower error rates in precision work
- Enhanced quality control capabilities
Long-Term Value
Economic Benefits
- Substantial ongoing electricity cost savings (30%+ reduction)
- Lower maintenance costs compared to HID lamp replacement cycles
- Reduced labor expenses for bulb changes and fixture servicing
- Significant ROI through combined energy and maintenance savings
- Protection against rising energy costs
Operational Excellence
- LED instant-on eliminates HID warm-up time delays
- Consistent light output maintains productivity standards
- Long LED lifespan (typically 50,000+ hours) reduces replacement frequency
- Minimal operational disruptions from lighting failures
- Reliable performance supports 24/7 manufacturing operations
Environmental Impact
- Smaller carbon footprint through reduced energy consumption
- Supports corporate sustainability and environmental responsibility goals
- Reduced waste from fewer bulb replacements
- Contribution to Brazil's energy conservation initiatives
- Demonstrates leadership in green industrial practices
Facility Enhancement
- Modern LED lighting improves facility appearance and reputation
- Better working conditions support employee satisfaction and retention
- Enhanced professional image for client visits and inspections
- Future-proof infrastructure aligned with industry best practices
Summary
Gillson's 120W LED High Bay Lights transform Brazilian factory with 340-unit installation, delivering 250 lux illuminance that outperforms 400W HID lamps by 10% while achieving over 30% energy savings, creating a brighter, safer, and more cost-effective industrial workspace.
Key Takeaways
This factory transformation project demonstrates Gillson Lights' industrial lighting expertise, delivering:
✓ 340 units deployed across factory, workshop, and warehouse areas
✓ 10% performance improvement over previous 400W HID system
✓ 250 lux illuminance exceeding client expectations at ground level
✓ 30%+ energy savings reducing operational costs significantly
✓ 70% power reduction per fixture (120W LED vs. 400W HID)
✓ 13,200 lumens per unit providing industrial-strength illumination
✓ Client satisfaction confirmed through superior results and ongoing partnership
Proven ROI Calculation
Energy Savings Analysis:
- Previous System: 340 units × 400W = 136,000W total power
- New LED System: 340 units × 120W = 40,800W total power
- Power Reduction: 95,200W (70% savings per hour of operation)
- Annual Savings: Substantial reduction in electricity costs supporting rapid payback period
Versatile Industrial Applications
Gillson High Bay Lights are proven solutions for:
- Manufacturing Facilities: Production lines, assembly areas, and quality control zones
- Warehouses & Distribution Centers: Storage areas, loading docks, and logistics operations
- Automotive Workshops: Service bays, maintenance areas, and repair facilities
- Food Processing Plants: Production floors meeting hygiene and safety standards
- Logistics Centers: Sorting facilities, packaging areas, and shipping zones
Ready to transform your industrial facility with energy-efficient LED lighting? Contact Gillson Lights today for a comprehensive lighting assessment and customized solution. Let us help you achieve superior illumination, dramatic energy savings, and enhanced workplace safety—just like we did for this successful Brazilian factory transformation.
