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An industrial LED lighting project should do more than simply reduce energy consumption. In production departments, light quality and uniformity affect work visibility, operator comfort and the precision of industrial activities. The project completed by Energia Europa for Plyform Composites shows how a lighting design developed around the actual needs of a facility can improve working conditions while significantly reducing installed power.
Table of contents
- Plyform Composites: lighting for high-precision work
- The requirements of the production departments
- The solution developed by Energia Europa
- The results of the project
- Reliability and light quality over time
- How to choose LED lights for industrial buildings
- Energia Europa solutions for industrial facilities
- Lighting and industrial energy efficiency
- A project built around production requirements
- Industrial LED lighting FAQ
Plyform Composites: lighting for high-precision work
Plyform Composites operates in the aeronautical sector, manufacturing and assembling composite material components for helicopters.
In this type of production environment, precision, process quality and work control are essential. The lighting system must therefore be designed around the activities actually carried out within each department.
Energia Europa’s work was not limited to replacing the existing lamps. The project began with an analysis of Plyform’s production requirements, with two main objectives: improving light quality in operational areas and reducing the facility’s overall energy consumption.
The requirements of the production departments
One of the main requirements was to improve lighting quality within the production departments.
Particular attention had to be paid to the area where laser projections are used on moulds. This required high lighting levels and illumination suitable for high-precision operations.
In industrial environments of this kind, installing more powerful fixtures is not enough. Light must be distributed correctly, avoiding poorly lit areas, excessive differences between work zones and conditions that may cause visual fatigue for operators.
Energia Europa therefore assessed several factors:
- the layout of the workstations;
- the characteristics of the production areas;
- ceiling heights;
- the activities carried out in each department;
- the required lighting levels;
- the need to adjust and control the light output.
This approach makes it possible to treat relamping as a genuine efficiency project rather than a simple replacement of existing lamps.
Are you considering upgrading the lighting in your industrial facility? Call Energia Europa on +39 0445 510 156 or fill in the contact form to speak with a specialist.
The solution developed by Energia Europa
To meet the requirements of Plyform Composites, Energia Europa installed ceiling-mounted LED fixtures capable of providing high-intensity, adjustable light.
The ability to control lighting is particularly important in industrial facilities where operating conditions vary from one department to another.
A material handling area, for example, does not have the same requirements as a workstation used for assembly, component inspection or high-precision manufacturing.
Through lighting design, Energia Europa can determine:
- the correct number of fixtures;
- their positioning;
- the most suitable power level;
- the appropriate optical system;
- the distribution of the luminous flux;
- the most suitable adjustment and control systems.
In this way, light is directed where it is genuinely needed, limiting dispersion, system oversizing and unnecessary energy consumption.
Lighting is only one of the areas that can be addressed to improve the overall performance of an industrial facility. Learn where energy is lost in industrial systems and how Energia Europa approaches industrial energy efficiency.
The results of the project
The project carried out at the Plyform Composites facility involved the installation of 450 lighting fixtures.
Installed power decreased from 120 kW before the project to 45 kW after the new LED fixtures were installed.
This represents a reduction of 75 kW, equal to 62.5% of the initial installed power.
Key project figures
- 450 lighting fixtures installed
- 120 kW of installed power before the project
- 45 kW of installed power after the project
- 206,000 kWh of energy savings
- 38 TOE
These results show how a correctly designed industrial LED lighting system can significantly reduce energy consumption without compromising the lighting levels required by production departments.
At Plyform, the reduction in installed power was accompanied by an improvement in light quality within the most sensitive areas of the facility.
Every industrial building has different heights, machinery and operational requirements. Call Energia Europa on +39 0445 510 156 or fill in the contact form to request an initial assessment of your existing lighting system.
Reliability and light quality over time
An industrial lighting system must maintain its performance even after thousands of operating hours.
The stated lifespan of a fixture is not the only factor that should be considered. Other important elements include:
- luminous flux stability;
- the reliability of electronic components;
- effective heat dissipation;
- the fixture’s suitability for the installation environment;
- consistent performance over time.
The feedback provided by Paolo Moretti, Production Manager at Plyform, highlights precisely this aspect.
Energia Europa supplied a product capable of meeting the high lighting requirements of the production departments. After more than four years of operation, the fixtures had shown no decline in quality or reliability.
This is particularly significant because it refers to a real installation operating under the normal working conditions of an industrial facility.
To reduce business costs in a structured way, companies must assess energy consumption, electrical systems and operating methods as a whole. Read Energia Europa’s practical strategies for energy saving in business.
How to choose LED lights for industrial buildings
The choice of LED lights for industrial buildings depends on the characteristics of the facility and the activities carried out inside it.
There is no single fixture suitable for every application. The solution must be selected by considering several key parameters.
Ceiling height
The mounting height affects the required power, beam angle and number of fixtures.
High industrial buildings may require industrial LED high-bay lights or reflectors capable of directing luminous flux towards the working plane. In lower buildings, it is more important to achieve uniform illumination while limiting glare.
Layout of the facility
Racking, machinery, production lines and suspended systems can obstruct the distribution of light.
Energia Europa therefore studies the positioning of each fixture in relation to the actual layout of the facility, avoiding the use of the same lighting configuration in areas with different functions.
Activities carried out
A logistics area, an assembly department and a quality-control workstation require different lighting characteristics.
In the Plyform project, the use of laser projections on moulds made it essential to pay particular attention to the areas dedicated to precision work.
Environmental conditions
Dust, humidity, high temperatures, aggressive substances and possible impacts require fixtures with suitable construction and protection characteristics.
For this reason, Energia Europa offers different solutions for industrial buildings, warehouses, logistics aisles and demanding production environments.
Energia Europa solutions for industrial facilities
The Energia Europa range includes five main solutions for lighting industrial facilities, warehouses, production buildings and logistics areas.
The right fixture is selected according to the lighting design, mounting height and activities carried out within the space.
e-CLOUD
e-CLOUD is a high-efficiency industrial LED fixture designed for low and medium mounting heights.
It is engineered to provide energy efficiency and visual comfort, with the option to integrate dimming systems and sensors.
e-LINE HOL
e-LINE HOL is designed for warehouses, logistics centres and racked aisles.
Its optical systems direct light along handling and storage areas, reducing dispersion towards non-operational spaces.
e-LINE
e-LINE is a sealed LED ceiling fixture suitable for industrial facilities, warehouses, workstations and covered car parks.
It can replace traditional fluorescent waterproof fixtures while providing uniform light distribution.
e-STAR²
e-STAR² is an industrial LED reflector designed for production facilities, warehouses and large covered areas.
Different power levels and beam angles allow the fixture to be adapted to the characteristics of the building. It can also replace traditional industrial high-bay lamps.
e-FACTORY
e-FACTORY was developed for industrial applications characterised by particularly demanding conditions.
It is suitable for facilities where durability, reliability and lighting control are priority requirements.
Energia Europa can combine different fixtures within the same facility, developing a specific solution for each production or logistics area.
Would you like to understand which fixtures are most suitable for your industrial building? Call Energia Europa on +39 0445 510 156 or fill in the contact form, describing the areas you need to illuminate.
Lighting and industrial energy efficiency
Upgrading the lighting system can be a practical first step towards reducing the energy consumption of an industrial facility, but it is not always the only area where action is required.
Energia Europa also operates in the field of Power Quality, analysing electrical phenomena that can affect the efficiency and reliability of industrial systems.
Industrial lighting and Power Quality must, however, be treated as two separate areas.
Lighting design focuses on the production and distribution of light through more efficient fixtures, suitable optical systems and advanced control technologies.
Power Quality solutions, on the other hand, focus on the quality of the electrical energy supplying machinery and industrial systems.
Keeping these areas distinct makes it possible to identify the causes of inefficiency more accurately and define a consistent improvement plan.
Discover what Power Quality is and why it is a strategic issue for industrial electrical systems.
Energia Europa also applies its lighting design expertise to environments that require specific optics and lighting levels. Explore Energia Europa’s LED floodlights for sports facilities.
A project built around production requirements
The Plyform Composites case study shows how industrial LED lighting can simultaneously improve visibility in production departments, energy efficiency and system reliability.
The presence of high-precision operations required a solution capable of providing high lighting levels, particularly in the area where laser projections are used on moulds.
Energia Europa responded by installing 450 high-intensity, adjustable ceiling-mounted LED fixtures, reducing installed power from 120 to 45 kW.
The outcome was not limited to energy savings. The solution continued to meet the lighting requirements of the production departments over time, confirming the importance of selecting high-quality fixtures and developing a correct lighting design.
Would you like to improve light quality in your production departments and assess the potential energy savings? Call Energia Europa on +39 0445 510 156 or fill in the contact form to request an assessment of your facility.
Industrial LED lighting FAQ
What are the benefits of industrial LED lighting?
A correctly designed system can reduce installed power and energy consumption, improve light uniformity, limit glare and reduce maintenance requirements.
Which LED lights are suitable for industrial buildings?
The choice depends on ceiling height, the layout of the space, the activities carried out and environmental conditions.
Energia Europa offers a complete range of industrial LED lighting solutions, including reflectors, industrial high-bay lights, sealed ceiling fixtures and products designed for warehouses and demanding industrial environments.
Is replacing existing lamps with LED fixtures enough?
Not always. Energia Europa starts with a lighting study to establish the correct number, position, power and optical system for each fixture, avoiding oversized systems or uneven light distribution.
How much energy can be saved by relamping an industrial building?
Savings depend on the existing system and its operating hours. In the Plyform Composites case, installed power decreased from 120 to 45 kW, with energy savings of 206,000 kWh.
What is the difference between a sealed LED ceiling light and an industrial high-bay light?
A sealed LED ceiling light is generally used in environments with low or medium mounting heights. An industrial high-bay light or reflector is normally used in taller buildings, where the luminous flux must be directed towards the working plane.
Does Energia Europa develop customised lighting solutions?
Yes. Energia Europa develops each lighting design according to the characteristics of the facility, the activities carried out and the energy objectives, selecting different fixtures for production departments, warehouses, aisles and technical areas.
