Overview
Honeywell Control Systems, a global leader in advanced technologies, faced a major challenge at their production facility in Newhouse, Scotland.
The large-scale factory required high-performance lighting capable of delivering exceptional lux levels for precision assembly and manufacturing.
At over 150 metres long, the production hall demanded a carefully designed solution that would not only meet strict technical requirements but also minimise energy use and operational disruption.
Challenges
The Newhouse site needed average lighting levels above 850 lux to ensure accuracy and safety in complex manufacturing tasks. With a competitively tendered project, Honeywell was also focused on energy efficiency and the ability to adapt to dynamic occupancy levels within the space.
Key issues included:
- Existing wiring infrastructure was outdated and its reuse uncertain.
- Low mounting heights posed risks of poor uniformity and glare.
- Honeywell preferred to use a control system manufactured by a sister company.
- Production could not be disrupted during installation.
- Sensitive equipment required careful handling and protection during work.
- Supply chain traceability and confidence in the specification were essential to the client.
In short, Honeywell needed a solution that combined technical precision, efficiency, flexibility, and minimal disruption.
The work
Kellwood Lighting worked closely with Honeywell and their appointed M&E consultants to design and deliver a tailored factory lighting solution. The strategy included:
| Element | Description |
|---|---|
| Full Rewire and Circuit Design | New electrical circuits prepared by consultants, using existing containment where possible to reduce costs. |
| Product Specification | Installation of 852 Bowden Series 90W DALI-dimmable luminaires, including 92 integrated 3-hour emergency fittings. |
| Energy-efficient Controls | Every pair of luminaires controlled by an individual sensor, enabling area-specific illuminance and optimised energy savings. Multi-step and gradual dimming ensured lighting adjustments were seamless and non-disruptive to workers. |
| Installation Strategy | Capacity identified in existing distribution boards meant new wiring could be installed and energised before removing old circuits. Work above sensitive machinery was carefully managed, with protection in place, and circuits were disconnected and energised over weekends to prevent downtime. |
| Emergency Lighting Design | Integrated seamlessly into the project for safety compliance. |
| Finishing Touches | New containment lids sourced for missing areas, leaving Honeywell with a modern and tidy upgrade. |
By combining technical expertise, product performance, and careful planning, Kellwood Lighting ensured the project was delivered efficiently and safely.
The results
The completed installation achieved:
- Average illuminance levels exceeding 850 lux across the 150m production hall.
- Zero production downtime throughout the project.
- A fully tested, efficient, and traceable lighting system delivered on time.
- A modern, energy-saving lighting solution with precise control and flexibility for future use changes.
Honeywell now benefits from a factory lighting system that supports high-precision manufacturing while minimising operational costs and energy consumption.
Conclusion
This project demonstrates Kellwood Lighting’s ability to design and deliver complex, large-scale factory lighting systems with zero disruption to production. Through detailed planning, advanced technology, and close collaboration with clients, Kellwood consistently delivers tailored, energy-efficient solutions.
If your business is looking to upgrade or optimise its lighting infrastructure, contact Kellwood Lighting today for expert advice and a bespoke solution.
74% forecast energy saving
>60% energy saving
