Case Studies

Almac Group see 'significant' energy savings...


The Almac Group is a global pharmaceutical contract research, development and manufacturing organisation employing 3,700 people throughout Northern Ireland, the United States and Asia. Early last year their Management team undertook a study on the existing efficiencies associated with lighting within their Clinical Services’ secondary production facility at their headquarters located in Craigavon, Co Armagh.

Almac Clinical Services

This was prompted by a number of key factors:

  • The variable quality of the current lighting *High maintenance requirements
  • Associated (high?) running costs.

AJ Hurst was delighted to have been approached by Almac to partner with them in their energy efficient lighting project. From its inception it became apparent that an ‘out of the box’ solution was not going to be an option as a number of obstacles had to be overcome.

The main challenge we faced with the project was the clean environment in which the fittings were located. The existing enclosure housings were unventilated and had to remain in place in compliance with the strict pharmaceutical industries procedures. We had to come up with a bespoke solution that could be retro-fitted into these existing housings, an additional benefit of being able to do this meant that any potential damage to the ceilings could be prevented.

The solution was to replace the existing 3 x 55 Watt PL lamps (183 Watts per fitting) with a made to measure surface mounted MODS L35 LED fitting from Dexeco. Each of these fittings gives a 3,500 lumen output at 26.8 Watts. A total of 310 fittings were supplied and installed with minimum disruption to staff and production.

The 310 fittings included 67 emergency fittings and 15 dimmable luminaires which were used in areas where light sensitive products are handled, were previously light filters had to be applied each time the products were used.

As a result the lighting load has reduced from over 51kW to approximately 8kW and at 70% utilisation the electricity saving is almost £400 per week (£21,000 per year approx.) The payback on investment is less than 1.5 years.

AJ Hurst surveyed the site and supplied Almac with a detailed audit and designs to suit their specific needs, this included a plan to adapt the existing equipment by removing the PL55s, control gear, wiring and diffuser, A detailed installation schedule was also agreed allowing us to install the new panels over a number of consecutive weekends to minimise operational disruption. As an added service AJ Hurst arranged for Dexreco (a subsidiary of the Dextra Group PLC) to collect the used fittings free of charge and to recycle them in line with the current WEEE legislation.

“What really made AJ Hurst’s solution unique against the competition was the complete ‘in-house’ package they offer as well as the impressive list of ‘blue chip’ clients they have already worked with. Other companies had to rely on a third party to either audit, advise or install, with AJ Hurst the project was carried out entirely by their own personnel giving us the reassurance that our project was in expert hands.”

“The outcome has been highly successful with production staff appreciating the even light levels within the production rooms whilst Management are very satisfied with the reduction in both electricity and maintenance costs.”

For additional information on this case study please download the ‘Sustainable Ireland’ article below.

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