Smart Logistics Lighting: Case Huhtamäki

In high-bay logistics rooms with high energy consumption costs, lighting plays a major role in workplace safety and energy efficiency. Read how Huhtamäki Foodservice Nordic achieved outstanding energy savings of 88 % and improved the working conditions of their logistics centre by investing in smart lighting.

The starting point

Huhtamäki is a global provider of food service packaging. The company is based in Espoo, Finland with 76 manufacturing units and 24 sales offices in 34 countries. Huhtamäki Foodservice Nordic has a plant and a logistics centre located in Hämeenlinna, Southern Finland.

The logistics centre in Hämeenlinna is a large high-bay warehouse with several long aisles. In addition to the warehouse, the building has a separate loading area. In 2017, the light levels of the logistics rooms varied between 143 to 300 lux. Back then, the warehouse was lit with high-pressure sodium vapour lights and the loading area with fluorescent tubes.

While there was enough light on some areas, the light levels were uneven and the lighting solution was not optimal to perform the work tasks on-site. Employees had trouble reading text and the lights caused some disruptive glare. Moreover, uneven electrical loads were a challenge.

Energy-efficiency-wise, there was room for improvement. With a lack of lighting control, the luminaires of the logistics rooms were constantly burning at full power. Ideally, the lighting is only on where and when lighting is needed.

The customer’s vision

As the previous luminaires were already reaching the end of their life cycle, Huhtamäki decided to modernise the lighting of the logistics rooms. With a new LED lighting solution and light management system, the customer was aiming to:

• Improve workplace safety and comfort
• Minimise lighting maintenance needs
• Optimise energy consumption and gain savings
• Invest in sustainable lighting with a greener footprint

The smart lighting solution

Greenled’s lighting solution for Huhtamäki Foodservice Nordic was a combination of smart lighting design, high-quality luminaires and adaptable lighting control.

The high-pressure sodium vapour lights of the warehouse were replaced with Greenled’s Omega luminaires and all fluorescent tubes at the loading dock were replaced with Gamma luminaires. The light levels of both areas now reach the EU-standards and ensure sufficient lighting for the work tasks on-site.

The optics of the luminaires were chosen to fit the high-bay space with long aisles. Special attention was given to the vertical surfaces of the shelves, which are now much brighter while glare is kept at a minimum. From struggling to read texts in orange light, both forklift drivers and supervisors now report a significant change in the level and tone of the lighting.

“On the driver’s seat, you need to see exactly where the forks are. You can’t be squinting while lifting and lowering heavy loads near the ceiling. The new LED lighting is glare-free, which is extremely important to us.”

Olli-Pekka Rokkanen, Supervisor of Electrical Work
Huhtamäki Foodservice Nordic Oy, Hämeenlinna

Image: The optics of the luminaires were chosen to fit the high-bay warehouse with long aisles. Special attention was given to the vertical surfaces of the shelves, which are now much brighter while glare is kept at a minimum.

Along with Greenled luminaires, the logistics rooms were equipped with motion detectors that automatically switch the lighting on and off to reduce energy use. With tens of aisles all varying in their usage rate, occupancy control significantly adds to the savings. At its best, occupancy control has brought added energy savings of 50 % in aisles with less traffic.

Greenled also installed the OSRAM ENCELIUM™ light management system to cover the entire illuminated area. The customer chose the ENCELIUM™ system as it allows them to adjust the lighting through the interactive Polaris 3D software visual interface and see detailed reports of the energy consumption. The ENCELIUM system facilitates the commissioning, usage and data analysis of the lighting installation, and provides comprehensive control of the whole lighting system via remote access, including energy monitoring.

Image: The reports of the ENCELIUM™ light management system demonstrate the significance of occupancy control. In this particular aisle with less traffic, the occupancy control (OCS) has brought added energy consumption savings of 50,52 %.

Compared to the previous lighting, the new LED luminaires save the customer 66,15 % in energy costs. On top of that, occupancy control brought added savings of 21,98 %. All in all, Huhtamäki logistics centre in Hämeenlinna reached outstanding energy savings of 88,13 % with its new lighting solution.

“Our expectations were met really well, and we’ve been happy with our lighting solution. The ENCELIUM™ light management system brings us flexibility, as we have the freedom to adjust light levels. With its detailed reports at hand, we can showcase just how much the new lighting brings us savings and develop our energy efficiency further.”

Olli-Pekka Rokkanen, Supervisor of Electrical Work
Huhtamäki Foodservice Nordic Oy, Hämeenlinna

The turnkey service

The whole lighting solution was provided as a turnkey service by Greenled, including planning, delivery, installation and commissioning. As a result, Huhtamäki Foodservice Nordic now has a sustainable lighting solution in their logistics rooms. The new solution saves them a lot of energy and more importantly, improves the workplace safety and comfort at the premises.

“Working with a turnkey service provider was important to us. From planning to delivery, the whole process was smooth and released resources at our end. Based on my experiences, I would recommend Greenled as a lighting solution provider.”

Olli-Pekka Rokkanen, Supervisor of Electrical Work
Huhtamäki Foodservice Nordic Oy, Hämeenlinna