LED Lighting Case Study
Brockhouse Forging
Industrial Lighting
West Midlands, UK
%
Annual savings
149,183 kWh
81 Tonnes CO2
Solas was appointed to design and install a lighting system for Brockhouse, a leading UK metal forging company supplying a wide range of international clients across industries including automotive, rail, defence, mining, and general engineering. The project aimed to reduce energy consumption, simplify control, and maintain high lighting standards across the busy manufacturing site.
The Client & Challenge
Brockhouse is a long-established name in metal forging, known for its precision engineering and technical excellence. The company required an energy-efficient lighting system that could reduce operating costs and carbon emissions while maintaining the same light quality that staff were accustomed to on the production floor.
The main challenge was ensuring that the new system matched or exceeded the performance of the existing lighting while introducing automation and efficiency improvements to meet sustainability goals.
The Solas Solution
Solas supplied and installed a robust high-level luminaire system designed for the demanding conditions of metal forging environments.
Lighting Design
The system was designed to deliver uniform LUX levels throughout the production hall, ensuring high visibility even in areas with airborne particulates and heavy machinery. Precision photometric modelling was used to optimise fitting layout and beam spread, providing consistent coverage while minimising glare and shadowing across workstations.
Energy Efficiency
Intelligent control gear was integrated into each luminaire, allowing lighting to operate automatically in response to occupancy and ambient light levels. This eliminated unnecessary use during non-operational hours, reducing overall consumption and extending fixture lifespan.
System Benefits
The LED solution cut energy and maintenance costs significantly while improving working conditions. The fittings’ robust design ensures reliability under high ambient temperatures and vibration, delivering consistent performance and safety compliance in a demanding industrial environment.
Project Delivery
The project was delivered with meticulous planning and close coordination to ensure production continued safely throughout the installation.
Solas oversaw every stage from design to commissioning, managing access, safety, and testing with precision.
The work was completed on schedule and to specification, achieving full performance without disruption to manufacturing.
Results & Impact
The installation achieved impressive energy savings and reduced environmental impact without compromising lighting quality. The introduction of automation and intelligent controls has further improved operational efficiency and ease of use for staff.
72% reduction
in annual lighting energy use
149,183 kWh
saved each year
81 tonnes of CO2
reduced each year
Engineering Efficiency in Forging
The Brockhouse project highlights how advanced LED lighting and automated controls can enhance efficiency, safety, and sustainability in heavy manufacturing.
Solas’ engineering expertise has enabled Brockhouse to maintain lighting quality while delivering substantial reductions in energy use and emissions.
We had energy efficient lighting installed purely for that reason – saving energy. I can say that the work has been carried out to the highest standard and we are extremely happy with it. The lighting we previously had was very good and from a user perspective we haven’t noticed much difference, which is good thing as the lighting demands are localized so comparison is a difficult measure in regards to previous lighting although the correct level of LUX has been achieved. However not having to switch the lights on and off manually will be a major benefit in our energy savings. The installations team were excellent, very professional and helpful. I don’t think the process could have gone any better and the after sales support in regards to ensuring a healthy supply is great.
– Stephen Walters, Finance Director, Brockhouse Group
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