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Case Study:Carlsberg
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Background |
Founded in 1992, the Israel Beer Breweries (IBBL) in Ashkelon is a “state of the art” brewery that produces Carlsberg and Tuborg beers. Initially, these products were imported from Copenhagen, but in 1995, local production began at a greenfield brewery. The IBBL brewery is situated above a large underground aquifer and uses its high quality water in the production process.
Carlsberg is currently the leading international brand in Israel, with Tuborg taking second place. IBBL is committed to innovation and has developed a unique, non-alcoholic beverage, “Malty,” which is very popular with children, women, and men. IBBL also manufactures a wide range of juice-based drinks and nectars under the name “Prigat”, the leading brand in Israel. It also imports Guinness, Weihenstephan, and Kilkenney beers and Belgian beers Leffe, Stella Artois, and Hoegaarden.
In 1997, the brewery won the “Defense of Industrial Environment” award, and in 2000, it received recognition from the Department of Environmental Affairs. Equipped with today’s latest technologies, the brewery has a 12,600 sqm production floor.
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Original Situation |
IBBL’s lighting system consisted of several hundreds of lamps using 400W magnetic ballasts. This lighting system consumed nearly 1 million KWH per annum, costing the brewery hundreds of thousands of dollars in annual maintenance and electricity.
Metrolight approached IBBL with the intriguing proposition of changing out their current lighting system with Metrolight’s Smart Electronic Ballast for HID™. By retrofitting their installation with the Smart Electronic Ballasts, IBBL was guaranteed cost savings and energy savings of between 40% – 60%.
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The Solution |
After detailed analyses and testing of the Metrolight lighting control systems and the Metrolight Smart Electronic Ballast for HID™, Carlsberg decided to move from traditional 400W magnetic ballast to electronic HID ballast, and to integrate the lighting installation with other building automation systems in the brewery. The Metrolight solution was installed in the Carlsberg plant in 2005.
The initial installation included the 320 Watt Metrolight Smart Electronic Ballast for HID™ set to 240 and 320 Watts Metal Halide lamp, instead of the 400 Watt magnetic ballast. The Metrolight Control™ software was fully integrated into IBBL’s control application platform enabling them to control their lighting requirements and thus save on energy consumption.
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The Result |
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IBBL realized energy savings of 46% without compromising light output and before implementing Metrolight Control™ software for intelligent control and dimming.
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| Features |
Before Installation |
After Installation |
| Lamp Power Wattage / Setup |
400 Watts |
240 Watts |
| Power Consumption W |
485 |
255 |
| Lumens Measured |
350 Lumens |
350 Lumens |
| Operating Hours |
24 |
24 |
| Electricity Cost $ |
0.10 |
0.10 |
| Total Installation Cost $ |
- |
$65,100 |
| Total Annual Electricity Cost $ (US$) |
$127,458 |
$67,098 |
| Average Annual Maintenance Cost1 (US$) |
$8,073 |
$4,012 |
| Total Annual Savings $ |
$64,421 |
| ROI |
1.01 |
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Notes:
1. Relamping every 2 years with magnetic ballast and 5 years with Metrolight Smart Electronic Ballast for HID™
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