Spiralling electricity prices and the recession have combined to hasten industry efficiency drives. As Keith Wyatt, from energy-efficiency specialist Somar International, explains, some companies are starting to see the light
Lighting can account for up to 25% of electricity bills in manufacturing facilities and a massive 60% in areas dedicated to storage or warehousing. And all too often it is a classic case of "the lights are on..but nobody's home" as bulbs are burning 24/7 in areas that receive relatively little pedestrian traffic. It is a waste of energy and, more importantly, money.
Until recently, remedying the problem by sourcing a viable, energy efficient lighting alternative was not easy. That is because while some low-energy fluorescent fittings can be effective at lower mounting heights, the increased number needed at heights above 5 metres to match light levels delivered by conventional lamps negated any savings.
New illumination technology, though, affords a means of tackling this "lost light" issue - and an increasing number of forward-thinking companies in the pharmaceutical arena are now making significant financial and environmental cost savings by switching to advanced systems.
One such eco-conscious business is tablet coating and design specialist Colorcon. The 20,000ft2 warehouse of its European HQ in Dartford, Kent, had been illuminated using 53 conventional High Intensity Discharge (HID) lights with a combined connected load of 19kW. Each of these metal halide lamps, running continually, costs around £300 a year and emits the same amount of CO2 as driving a family saloon car 14,000km.
Colorcon recognised the problem - internationally the company spends around US$4m (Euro 3m) a year on energy - and launched an initiative to reduce its annual power consumption by 10%.
Light provision has been a particular focus and led the Dartford plant to replace its metal halide bulbs with an equal number of energy-efficient Somar Eluma fittings with a combined connected load of around 10kW. Early indications are that the move will save £6,500 a year, a 64% reduction, and also 29.7 tonnes of carbon.
Such energy savings are possible as a result of Eluma's special reflector, which boasts 95%, and its intelligent sensor system that dims or switches off lights when areas are unoccupied.
It also decreases output according to natural light levels. Colorcon's factory benefits from plenty of natural light coming in from skylights and windows - but the outgoing lights burned at the same lux levels irrespective of incoming daylight.
Medical and pharmaceutical packaging manufacturer Amcor Flexibles, which designs and makes barrier laminations for pharmaceuticals packaged in sachets, pouches, and stick, strip and blister packs, is another company that is reaping the benefit of embracing "green" light technology.
In total, 175 Eluma lights were phased in across production facilities and warehouses at its Bristol manufacturing base throughout 2008. Each fitting replaced two metal halide lamps, yet still managed to increase overall light levels.
Electrical engineer Steve Seward initially estimated the payback period of the £47,400 project to be 18 months - but energy price increases last year means the lights will have paid for themselves in less than a year. He now calculates the annual energy saving to be worth around £60,000, while the move has reduced Amcor's carbon footprint by 236 tonnes a year.
And as the Eluma fittings, along with other eco-aware systems, feature on DEFRA's Energy Technology Product List, both Amcor and Colorcon have been able to claim an Enhanced Capital Allowance tax break of 28% against the purchase cost and installation.
Many businesses are still sceptical about "green" technologies: they are concerned it will be costly or don't want to be accused of tokenism, imagining it will make little difference. But these results show that such technologies can have an impact.
It is encouraging that companies such as Colorcon and Amcor take their social responsibilities very seriously and are researching new, proven green technologies that also boost their bottom line.