LED Lighting Case Study
CastAlum
Industrial Lighting
Wales, UK
%
Annual savings
230,300 kWh
125 Tonnes CO2
Solas was appointed to design and deliver a lighting solution for CastAlum, a leading aluminium diecaster supplying components to the global automotive industry. The project aimed to reduce operational costs, cut carbon emissions, and enhance light quality across the company’s production facility.
The Client & Challenge
CastAlum is an internationally recognised manufacturer of precision aluminium diecast parts. The company operates a large, high-intensity production environment where consistent, efficient lighting is essential for both quality control and worker safety.
The existing lighting system was outdated, expensive to maintain, and failed to deliver the necessary light levels. CastAlum sought an energy-efficient alternative that would help meet environmental targets while improving visibility and reliability across the site.
The Solas Solution
Solas supplied and installed a new LED high-level luminaire system designed to meet the rigorous demands of industrial production environments.
Lighting Design
The system was engineered to deliver consistent, high-performance illumination throughout the facility.
Energy Efficiency
The upgrade replaced inefficient fittings with Solas’ high-level luminaires, achieving substantial reductions in energy use and maintenance costs.
Control System
The upgrade replaced inefficient fittings with Solas’s high-level luminaires, achieving substantial reductions in energy use and maintenance costs.
Project Delivery
The installation was delivered safely and efficiently, with no disruption to production.
Solas managed all aspects of the design, supply, and commissioning process, ensuring the project ran smoothly from start to finish and met all performance expectations.
Results & Impact
The new lighting has transformed light quality and operational efficiency within the facility, supporting CastAlum’s environmental and financial objectives.
74% reduction
in annual lighting energy use
230,300 kWh
saved each year
125 tonnes of CO2
reduced each year
Engineering Sustainable Performance
The project demonstrates how intelligent lighting design can improve efficiency, safety, and environmental performance in high-demand industrial environments.
By combining technical precision with energy-saving innovation, Solas has helped CastAlum achieve lasting operational and carbon savings.
The lighting that Solas installed for us is far better and more efficient than the lighting we had previously. The old lighting was dim and needed replacing regularly which worked out expensive. We are all very happy with our new lighting and it’s saving a great deal of money on our electricity consumption. The lights are on a sensor which is great because they don’t need to be on all the time. The whole process ran smoothly and I am really happy with the end result.
– Simon Grimwade, Process Maintenance Manager, CastAlum
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