Fisher and Paykel Healthcare Auckland
Fisher and Paykel is an iconic New Zealand company, known for their world-leading engineering and design. Their involvement in health care began in the late 1960s.
Fisher and Paykel Healthcare manufactures, designs and markets sophisticated products and systems for use in respiratory care, acute care and the treatment of obstructive sleep apnoea. They are one of New Zealand’s major exporting companies and their products and systems are sold in 120 countries worldwide.
The O’Hara building is a state-of-the-art, multi-building facility made up of offices, clean rooms housing task-critical manufacturing, and warehouses. It is a very large, single-level facility with a high ceiling stud.
The site was primarily lit by T5 and T8 fluorescent tubes.
The light quality in the clean room was poor and needed to be raised by 200 lux. However there was a prerequisite for the existing custom clean room lights to be retained.
The tubes and ballasts in the clean room luminaire regularly failed, and as specialised access equipment was required to change them, this was an expensive exercise. Even more critical though, was the interruption to production and the risk of contamination of the clean room environment during maintenance.
Fisher & Paykel’s objectives were to lift light levels in the facility (by 200 lux), reduce operating costs by eliminating unscheduled maintenance, and to improve sustainability by reducing the size of the site’s carbon footprint.
The project scope was to provide an end-to-end turnkey solution including: definition of requirements, specification and manufacture of products, project management of the installation, commissioning, reporting, and EECA compliance.
BLS Lighting Solutions
BLS met with Fisher and Paykel Healthcare Facilities Manager Dave Cuff to gain an understanding of the site's commercial and operational imperatives.
The impetus for changing their lighting scheme was the need to raise lux levels by 200 lux, to reduce power consumption, eliminate unscheduled maintenance, and to reduce the size of their carbon footprint.
BLS completed a review of the site, recording hours of operation, site dimensions, lux levels, and the hanging height, number, location and type of luminaire.
Preliminary analysis of the site audit data indicated that there was a sound economic case for upgrading Fisher and Paykel’s lighting. BLS recommended a formal review of the lighting design and costs.
BLS undertook extensive modelling of the clean room production area. They established that a one-for-one replacement of the existing fluorescent tubes with BLS T8 LED tubes was the best option. This would lift end-of-life lux levels by 200 lux and by using existing wiring points, it would minimise the installation costs.
Lighting controls were ruled out for the manufacturing plant as to retrofit these was not economically feasible.
A mix of the BLS UT T8 1,200mm, 24W and 20W LED tubes were specified to replace the 1,200mm 36W fluorescent tube. The BLS LED tubes produce 2,880 and 2,400 directional lumens and was specified with a colour temperature of 4,000 kelvin.
BLS verified that F&P Healthcare qualified for an EECA grant and managed the application, compliance process and payment of the grant on completion of the project.
Our Specified Solution.
BLS developed a comprehensive installation plan and project managed the installation, commissioning, EECA reporting and production of the project case study.
|The T8 LED Tubes were provided with a 5-Year L70 Warranty|
Phased Project Implementation
BLS coordinated with operational staff to develop an end-to-end project plan, which detailed tasks, processes, site-specific requirements, dependencies, and outputted the critical path to completion.
Measurements and Verification
BLS installed meters on lighting circuits to measure power consumption before and after the upgrade, in order to verify savings.
BLS appointed and briefed an electrician from their contractor pool; scheduled an on-site visit to meet with Fisher & Paykel’s operational staff; defined health and safety requirements and agreed an optimal install window.
BLS met on-site with Fisher & Paykel to review the installed solution and to verify that projected energy savings and lux levels were to brief.
BLS prepared a project case study and report for Fisher & Paykel and the EECA, detailing energy savings.
They submitted the EECA report, finalised grant paperwork, and paid the grant to Fisher & Paykel.
The results of the new BLS lighting scheme speak for themselves. Prior to the installation, there had been regular failures of the ballasts in the fluorescent tubes at the F & P facility. Maintenance was difficult and disruptive given the height of the ceiling (six metres) and the sensitive nature of the production process. The risk of contamination was high and specialist access equipment was required.
In order to meet Fisher & Paykel’s specific objectives, BLS developed the Infinity Litebox. This is a product that has now become the gold standard for clean room environments. The Infinity can be easily accessed from the ceiling so there is no risk of contamination of the environment. BLS was able to reuse the existing clean room troffers to ensure the installation process did not introduce any new contaminants.
The BLS solution also halved Fisher and Paykel’s original power consumption while generating a 40% increase in light levels.