LED Lighting Case Study
Eurocell plc
Manufacturing Facility
Alfreton, Derbyshire
%
Annual savings
168,124 kWh
91 Tonnes CO2
Solas was appointed to design and install an intelligent LED lighting system for Eurocell plc, a leading UK manufacturer of precision PVC-U extrusion products. The project aimed to reduce energy use, improve light levels across the production facility, and support the company’s sustainability commitments under ISO 14001 accreditation.
The Client & Challenge
Eurocell plc operates from a purpose-built 80,000 sq ft extrusion and tool-making facility, supported by over 260,000 sq ft of stockholding capacity and employing around 1,000 people nationwide.
An audit of the existing lighting system revealed several opportunities for improvement. The outdated luminaires were inefficient, produced poor-quality light, and required frequent maintenance due to regular lamp failures. This not only impacted energy performance but also increased operational costs and affected working conditions across the facility.
The Solas Solution
Solas designed and installed a new lighting system incorporating 60 intelligent LED luminaires throughout the production facility.
Lighting Design
The system was engineered to deliver uniform, high-quality illumination suited to precision manufacturing.
Efficiency
Intelligent controls optimise performance, ensuring light levels respond dynamically to operational needs while minimising energy waste.
System Benefits
The installation has enhanced visibility, improved working conditions, and provided a significant reduction in energy consumption and maintenance requirements.
Project Delivery
The installation was delivered with precision and pace, allowing the factory to stay fully operational throughout.
Working in close collaboration with Eurocell’s engineering team, Solas planned every stage to ensure safety, efficiency, and minimal disruption.
The result was a seamless transition to the new lighting system, completed on time and without compromise to production.
Results & Impact
Following installation, the lighting performance and overall energy efficiency improved dramatically. Electricity consumption was reduced by more than half, maintenance costs decreased, and the project made a measurable contribution to Eurocell’s group sustainability targets.
67% reduction
in annual lighting energy use
168,124 kWh
saved each year
91 tonnes of CO2
reduced each year
The entire process of purchasing, delivering and installing our new lighting was easy and efficient. The health and safety and general environment was great and the installations team were professional and tidy. I’m really happy with the final product and highly recommend this lighting range to other companies.
– Mike Keen, Engineering Manager, Eurocell plc
Driving Performance Through Sustainability
The project has transformed lighting performance across Eurocell’s manufacturing facility, providing consistent, efficient illumination that supports the precision of daily operations. The new system delivers measurable gains in energy efficiency, reliability, and visual quality while reducing long-term maintenance demands.
By pairing smart design with technical accuracy, Solas helped Eurocell strengthen its operational resilience and progress toward its wider sustainability goals.
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