Vistakon Limerick, a division of Johnson & Johnson Vision Care, operates a world-class manufacturing facility in Limerick, Ireland, specialising in the production of advanced contact lenses. Renowned for its innovative high-volume manufacturing processes, the facility upholds a strong commitment to quality, safety, and sustainability while delivering cutting-edge vision care products globally.
When Vistakon decided to transition from fluorescent lighting to energy-efficient LED solutions, Solite’s Dublin-based team was engaged to support the upgrade. This initiative was driven by three key factors:
- Enhancing the lit environment
- Reducing energy consumption and carbon emissions
- Addressing the obsolescence of fluorescent technology.
A major challenge for Vistakon and Suir Engineering was maintaining the integrity of the built environment, particularly in controlled spaces where lighting forms an integral part of the room's fabric. Replacing entire luminaires in such settings can be disproportionately expensive and time-consuming. To address this, a retrofit gear tray solution was chosen, balancing efficiency with minimal disruption.
Solite provided approximately 1,100 custom-designed LED gear trays, tailored to fit both their legacy luminaires and those from other manufacturers. Collaborating closely with Suir Engineering, Solite ensured the gear trays met exacting requirements, incorporating features such as aligned terminal blocks to match existing cable entry points, saving valuable installation time. Additionally, strict weight limits for the trays were addressed through innovative engineering, using lightweight materials and strategic cut-outs to minimize weight without compromising performance.
Extensive testing in Solite’s laboratory ensured the gear trays and diffusers were optimized for performance. Photometric data from these tests enabled precise lighting schemes, guaranteeing compliance with required lux levels. The result was a highly successful and efficient lighting upgrade for the Vistakon Limerick facility.
The projected savings from the retrofit amounted to €50,000 annually, alongside a significant reduction in carbon emissions of 110,500kg per year. With rising energy costs, the financial savings and return on investment are now expected to be even greater, delivering reduced running costs and a shorter ROI period.
Retrofit gear tray solutions offer numerous advantages, including:
- Faster installation times
- Reuse of existing luminaire bodies, promoting sustainability
- Access to the latest lighting technology at a fraction of the cost of new luminaires
- Enhanced lit environments
- New product warranties