When replacing LEDs is not enough

From ageing LEDs to intelligent lighting

At the ModusLink Czech Republic industrial and logistics site in Brno-Slatina, the original LED system had been in service since around 2013–2014. After almost ten years of operation, failures in the OMS Grafias luminaires became more frequent, increasing the risk of unplanned outages. In 2023, part of the production hall lighting failed.

Instead of repairing individual luminaires one by one, we chose to modernise the entire lighting system across 14,500 m². The aim was more than simply replacing old LEDs with new ones. We combined the new luminaires with intelligent Savee controls so that the lighting could adapt to the actual needs of production and logistics.

The road to savings

We replaced the original system with industrial HighBay LED luminaires rated at 139 W with a luminous flux of 22,500 lm. The project covered around 340 lighting points. We added Savee controls to the new luminaires, because replacing LEDs alone does not exhaust the potential for savings.

Savee allows the site to be divided into logical zones, each controlled according to its actual use. It supports operating schedules, independent zone control, automatic adjustment of light intensity, the use of available daylight and central management of lighting settings. Lighting no longer needs to operate in the same way throughout working hours.

A significant part of the energy efficiency comes from adjusting luminaire output to where, when and how much light is actually needed. More efficient luminaires and intelligent controls complement each other.

We divided the luminaire replacement and control installation into stages according to the current use of production and storage areas. Careful preparation and coordination meant the site remained operational without a significant impact on the customer's production processes.

ModusLink gained a lighting system that can be adjusted and optimised as technologies, workstation layouts, storage areas and operating patterns change. The modernisation combines greater reliability and energy savings with a foundation for the long-term digitalisation of the building's lighting.

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Expected annual financial savings of CZK 506,510

The investment payback period is 4.98 years

The payback period is based on 2023/2024 electricity prices. Expected savings in electricity costs for lighting are around 44% compared with the original system.