Energy Saving Lighting Report

By
Bimsara Amarakoon
Thimalka Weerasignhe

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Abstract
Today a number of renewable energy technologies are available for power generation, but fossil fuels
are still providing a dominant share nevertheless. In order to decrease the electric bill and save our
environment, energy conservation is always crucial. In this report a very interesting idea is presented
which is economically viable to reduce electricity usage in Lanka Sugar Factory Private Limited –
Pelwatte division. An effort has been made to estimate the amount of energy that could be saved in the
factory section. Although there are many ways to reduce the consumption of electricity in this building
but here the emphasis is on changing light bulbs inside each department of the factory. The purpose of
the report is to figure out monthly and annual electricity saving by replacing traditional light bulbs by
LED light bulbs in the building under consideration. The total investment required and the payback
period is also presented.

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Table of Content

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Introduction
Lanka Sugar Company PVT ltd, is a leading factory in production of brown sugar in our country and in the
world. In this factory there are main premises. Like, Production factory, villages, quarters, and distillery.
According to this project only production factory premises is considered. According to power saving
strategies, there are lot of ways to reduce the power in the factory. A one way is by replacing high
power lights to similar LED powered lights. In this premises normally there are like 1000 different types
of bulbs. From them around 50% were working in twenty-four hours. When replacing bulbs, our main
aim is to give the same output from the LEDs that given from the normal bulbs.

This energy saving lighting report has been produced to show you the advantages of switching over to
Ideal. Lights unique range of retrofit LED Lighting. As will be seen, significant savings can be made - both
from a fiscal point of view and environmental view - through the reduction of your carbon footprint.

Ideal Lights
Ideal Lights was launched in 2005, its prime focus today is to combine the latest lighting technologies
and materials in designing, testing, certifying and supplying ultra-low-energy, long-life, environmentally
friendly, retrofit lighting solutions. In addition to supplying lighting products to end users, Ideal Lights
offers a fully packaged service which includes:

 Detailed lighting energy audit reports, pinpointing where replacement lamps will reduce energy
consumption.
 An outline installation programmed and, if required, the provision of specialist installation
engineers and equipment.
 Assistance with applying for interest-free funding from the Carbon Trust or Salix, as appropriate.
 Fully WEEE compliant disposal of old lamps, bulbs and fittings.

LED Technology
Ideal lights have a unique, never before seen, range of LED lighting solutions. Our LED products are the
brightest on the market, offering, for the first time, usable levels of general lighting. New generation
LEDs generate 3 to 5 times more light than previous LED technology and have energy savings of up to
90%, when compared against traditional lighting technology. Ideal specializes in retrofit products, which
install with the least amount of disruption possible. All of our products have undergone extensive
testing and certification to ensure they meet stringent standards and have the longest life possible. With
average service life of up to 50,000 hours, LED lamps are perfect for hard-to-reach and maintain fixtures.
Besides reducing maintenance, they substantially extend bulb replacement cycles, further cutting costs.

LEDs reach full brightness almost instantly unlike compact fluorescents that can take more than minute
to achieve their maximum output. Existing lighting technologies are omni-directional and require
external, inefficient reflectors to focus the light they emit. LED lighting is by its nature a directional light
source, so that light is used efficiently and distributed to exactly where it is needed.

Enhanced Capital Allowances

White LED Lighting is now on the Government's Energy Technology List, so that all our LED replacement
products qualify for Enhanced Capital Allowances, enabling companies to write off this capital
expenditure in the first year.

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Carbon Trust and Salix Loans
SMEs and public sector organizations may qualify for interest-free loans that absorb the upfront costs of
an energy-saving lighting project. Loan repayments are spread over the length of the project's payback
period so that the cost is effectively funded by ongoing energy savings.

Secondary Saving Benefits

With the extended life span of LED Lamps, there are significant savings to be made with reduced
maintenance and lamp replacement costs. Other secondary benefits include reductions in air
conditioning costs due to the significantly reduced heat generated by LED lamps.

Reduced Deterioration of Cabling and Fittings

With a significant reduction in electrical current draw from LED lights, wiring and electrical fittings will
suffer less from deterioration and hence last longer.

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Lighting Replacement Proposal
Significant savings can be made by replacing the following lighting types:

 Halogen
 Incandescent lighting
 Fluorescent lighting
 High intensity discharge lighting
 General Lighting

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Savings Overview
Based on the information gathered from the lighting survey, and our proposed replacement lighting
solution, we can determine your current annual energy usage and costs:

Current proposed
Annual Lighting Energy Usage 395,286 74,341.08
(kWh)
Annual Lighting Energy Costs 4,171,632 811,548.762
Annual Lighting Replacement 144,755.63 40,090.508
Costs
Total Annual Cost 4,316,387.63 851,639.270

Reduced Lighting Energy Costs by Rs. 3,464,748.36 per year

Overall Lighting Energy Savings of 80.27 %

Total Savings: Rs. 3,464,748.36 per year

Benefits

 Significant energy cost savings.

 Improved lighting quality in various areas.
 LED products are on the ECA list (Enhanced Capital Allowance), allowing significant tax savings.

Maintenance costs significantly reduced

 LED products come with a minimum 1-year warranty and last an average of 50,000 hours.
 All LED products are designed to be drop-in replacements, using existing fittings. Some fittings
may require a simple modification.
 CFL products come with a 1-year warranty and last up to 20,000 hours

Environmental Benefits

 Significant reduction in carbon reduction.

 LED Products can be disposed of more safely as they contain no mercury or lead content.

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Energy Costs

Annual Lighting Energy Costs

4,500,000.00
4,000,000.00
3,500,000.00
3,000,000.00
2,500,000.00
2,000,000.00
1,500,000.00
1,000,000.00
500,000.00
0.00
Current Praposed

Series 1

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Current Energy Usage Per Area

Boiler Mill Power Mechanica Process Admin Loading point

house l workshop house
Cost per a day 2872 2225 1113 816 1736.9 566.62 2252.155
(Rs)
No. of Units 282.96 211 96.58 71.4 169.21 63.15 203.7
per a day
Cost per a 86160 66861 33390 24551.4 52110 16998.6 67565
month (Rs)
No. of units per 8488.8 6330 2897.4 2142 5076.3 1894.65 6111
a month

Monthly Energy Usage per Area Comparison

Energy Usage per Area

Boiler Mill Power house Mechanical workshop

Process house Administation Unloading point

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Replacement Energy Usage Per Area

Boiler Mill Power Mechanical Process Admin Loading point

house workshop house
Cost per a day 337.77 481.90 376.39 268.58 412.54 360.87 16.22
(Rs)
No. of Units 31.85 42.10 33.09 23.61 36.21 31.60 8.01
per a day
Cost per a 10133.39 14457.28 11291.94 8057.48 12376.21 10826.14 486.61
month (Rs)
No. of units 955.5 1263.21 992.88 708.48 1086.3 948.24 240.48
per a month

Monthly Energy Usage per Area Comparison

Energy Usage per Area

Boiler Mill Power house Mechanical workshop

Process house Admin Unloading point

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Appendix A - Current Lamp Statistics
Buildings in Factory premises.
1. Boiler.
2. Mechanical Workshop.
3. Mill.
4. Power house.
5. Process house.
6. Unloading point.
Types of bulbs use in these departments.
1. Tube light 4 feet (36W).
2. Tube light 2 feet (18W).
3. Halogen (1000W).
4. Halogen (500W).
5. Mercury vapor bulb with Chalk (250W & 400W).
6. Mercury Vapor bulb without chalk (250W & 400W).
7. Sodium vapor bulb (250W/400W).
8. CFL (25W/40W).
9. Filament Bulb (75W).

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Number of bulbs in buildings above mentioned
BULB TOTAL BOILER MILLS POWER MECHANICAL PROCESS UNLOADING
TYPE AMOUNT HOUSE WORKSHOP HOUSE AREA
TUBE 161 63 10 13 8 35
LIGHT 4
FEET 36W
TUBE 10 5
LIGHT 2
FEET 18W
HALOGEN 22 7 4 11 6
100W
HALOGEN 14 6 1 3 12
500W
MERCURY 20 16 13
WITH
CHALK
250W
MERCURY 106 25
WITH
CHALK
400W
MERCURY
WITHOUT
CHALK
250W
MERCURY
WITHOUT
CHALK
400W
SODIUM 2
VAPOR
400W
SODIUM
VAPOR
250W
CFL 40W
CFL 25W 120 15 3 3 6 12
FILAMENT 2
75W

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Boiler
This is a twenty-four-hour working factory and there are mainly four shifts. They are, main three shifts
and general shift. According to these time lines the number of bulbs which using was calculated.

Type (Boiler) 6.00 A.M - 2.00 2.00 P.M. - 10.00 10.00 P.M. - 6.00 7.30 A.M. - 4.30
P.M P.M A.M. P.M.
Tube light 4ft 50 50 63 50
Tube light 2ft
CFL 24W 15 15 15 15
Mercury Vapor
with chalk 250W
Mercury vapor 3 3 8 3
with chalk 400W
Halogen 500W
Halogen 1000W
Sodium Vapor
250W
Sodium Vapor
400W
Filament 75W
100W Halogen 7 7 7 7

Above table shows how many lights were used in the shifts. Likewise following are other premises used
lights.

Mill house
Type (Mill) 6.00 A.M - 2.00 2.00 P.M. - 10.00 10.00 P.M. - 6.00 7.30 A.M. - 4.30
P.M P.M A.M. P.M.
Tube light 4ft 10 10 10 10
Tube light 2ft
CFL 24W 3 3 3 3
Mercury vapor
with chalk 250W
Mercury vapor 5 5 10 5
with chalk 400W
Halogen 500W 1 1 4
Halogen 1000W
Sodium Vapor
250W
Sodium Vapor
400W
Filament 75W 2 2 2 2
100W Halogen 4 4 4 4

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Power House.
Type ( Power 6.00 A.M - 2.00 2.00 P.M. - 10.00 10.00 P.M. - 6.00 7.30 A.M. - 4.30
house) P.M P.M A.M. P.M.
Tube light 4ft 13 13 13 13
Tube light 2ft 5 5 5 5
CFL 24W 3 3 3 3
Mercury vapor
with chalk 250W
Mercury vapor 8 8 8 8
with chalk 400W

Process House.
Type (Process 6.00 A.M - 2.00 2.00 P.M. - 10.00 10.00 P.M. - 6.00 7.30 A.M. - 4.30
house) P.M P.M A.M. P.M.
Tube 4ft 30 30 30 30
Halogen 250W 3 3 3 3
Mercury vapor 10 15 15 10
250W
CFL 24W 12 12 12 12
100W Halogen 11 11 11 11

Mechanical workshop.
Type (Mechanical 6.00 A.M - 2.00 2.00 P.M. - 10.00 10.00 P.M. - 6.00 7.30 A.M. - 4.30
workshop) P.M P.M A.M. P.M.
Tube light 4ft 8 8 8 8
Tube light 2ft
CFL 24W 6 6 6 6
Mercury vapor
with chalk 250W
Mercury vapor 6 6 6 6
with chalk 400W

Admin
Type (Admin) 6.00 A.M - 2.00 2.00 P.M. - 10.00 10.00 P.M. - 6.00 7.30 A.M. - 4.30
P.M P.M A.M. P.M.
Tube 40W 15 26 26 15
CFL 25W 61 67 67 61

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Loading Point.
Type (Loading 6.00 A.M - 2.00 2.00 P.M. - 10.00 10.00 P.M. - 6.00 7.30 A.M. - 4.30
point) P.M P.M A.M. P.M.
100W Halogen 3 5 6 3
1000W Halogen 5 8 10 5

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