Overview
A leading Middle Eastern steel manufacturer partnered with Kellwood Lighting to overcome a long-standing problem: the short lifespan of their lighting in extreme production hall conditions.
The client also sought reduced energy consumption and a lower carbon footprint, while maintaining worker safety and minimising maintenance. Kellwood provided a bespoke technical solution that met all requirements.
Initial Challenges
The project posed significant technical and logistical hurdles:
| Challenge | Description |
|---|---|
| Extreme heat | Production areas were initially tested to have ambient temperatures approaching 80°C. |
| Elevated mounting positions and gantry levels | Lights were mounted at heights up to 40m, requiring a fitting capable of delivering light to operating areas at a variety of levels. |
| Dust and dirt accumulation | Airborne dirt and dust generated from steel processing lowered visibility, and accumulated on surfaces. |
| Complex import requirements | Specific customs and finance requirements needed to be met. |
The work
- Lighting Designs: Detailed designs identified optimal optics and lumen outputs for the production halls.
- Bracketry Review: Product bracketry was assessed for compatibility with existing infrastructure.
- Staged Supply: Follwowing an initial trial, products were delivered in phases to align with client’s operational schedule.
Kellwood delivered an initial solution to trial:
| Initial Challenge | Solution |
|---|---|
| Operating Temperature | Parker 3 Series luminaires, designed for up to 80°C operation |
| High Light Output | 450W option delivered ~56,000 lumens with tailored optics |
| Light Distribution | Precision optics selected to deliver light to multiple levels |
| Visibility | Low colour temperature (3000K) improved visibility in dusty, low-contrast environments |
| Installation Infrastructure | Universal bracket system allowed flexible installation |
| Logistics | Kellwood’s export team managed complex international import processes |
The results
During on-site trials, it was identified that infrared radiation above furnace areas was melting polycarbonate optics, indicating that ambient air temperature was not the sole challenge. Following the initial trial period these new challenges were solved:
| Further Challenge | Solution |
|---|---|
| Radiation damage of polycarbonate optics in furnace zones | Hybrid tempered glass optics were installed in critical areas |
| Excessive radiant heat could be impacting drivers | Remote driver assemblies were developed, allowing components to be mounted away from direct radiation, with the added benefit of raising safe operating conditions for light engines to 90°C |
| Additional Verification: Use of a grey fixture finish to reduce heat absorption was maintained. |
Kellwood Lighting delivered a robust, energy-efficient system capable of withstanding one of the harshest industrial environments. The client benefited from:
- Extended luminaire lifespan despite extreme conditions
- Reduced maintenance requirements at elevated mounting heights
- Improved visibility and worker safety
- Lower energy consumption and carbon footprint
74% forecast energy saving
