Project Overview
Our technical team attended Barnsley College to carry out a comprehensive site survey following a request to provide a solution that would retain the existing luminaires while upgrading the lighting system to LED technology. The objective was to improve energy efficiency, reduce maintenance requirements, and enhance lighting performance whilst minimising disruption and preserving the existing infrastructure.
The Challenge
The primary challenge of this project was designing and manufacturing bespoke LED gear trays that would fit within the existing continuous recessed luminaires, allowing the original fittings to be retained. In addition, the existing diffusers had deteriorated and yellowed over time, impacting both the appearance and lighting performance. A further complication was that the original diffuser featured a unique profile that was no longer readily available. To overcome this, custom tooling was commissioned to accurately replicate the original profile, enabling the manufacture of replacement diffusers to the exact specification required. This ensured the refurbished luminaires maintained their original aesthetic appearance while benefiting from the improved performance, efficiency, and longevity of a modern LED lighting solution.
The Solution
Design
- Lighting calculations
- Product selection
- Bespoke modifications
Engineering
- Custom fabrication
- Mounting solutions
Manufacturing
- Sheet metal fabrication
- Powder coating
- Assembly
- Testing
Project Details
| Client | Barnsley College |
| Sector | Education |
| Location | Barnsley, UK |
| Products | Bespoke LED Gear trays |
| Services | Design, Manufacture, Supply |
Manufacturing Capability
Using detailed site survey information and precise measurements, we designed and manufactured custom LED gear trays to fit seamlessly within the existing recessed luminaires.
Technical Performance
| Requirement / Standard | Result / Compliance |
|---|---|
| Average Lux Level | 300 Lux |
| Colour Temperature | 4000K |
| CRI | >80 |
| Maintenance Life | 102,000+ Hours |
Installation
Our manufacturing team retains the design specifications, tooling, and production data for the bespoke gear trays and diffuser profiles, ensuring consistency and quality across all future production runs. This enables us to provide repeat orders efficiently, with each batch matching the original retrofit solution and maintaining a uniform appearance and performance throughout the site.
The phased approach provides the college with a cost-effective and sustainable route to modernising its lighting infrastructure, delivering the benefits of LED technology while extending the service life of the existing luminaires and reducing unnecessary waste.
Project Outcomes
- Improved light quality and distribution through the installation of new LED gear trays and replacement diffusers.
- Significant reduction in energy consumption compared with the previous fluorescent lighting system.
- Reduced maintenance requirements due to the longer lifespan and reliability of LED technology.
- Retention of the existing luminaires helped minimise waste and supported the college's sustainability objectives.
- Cost-effective alternative to a full luminaire replacement programme.
- Improved aesthetic appearance by replacing yellowed and deteriorated diffusers.
- Phased upgrade programme allows works to be completed in line with budget availability and operational requirements.
- Ongoing manufacturing capability ensures consistent quality and supply for future orders.
- Extended service life of the existing lighting assets whilst delivering the benefits of a modern LED lighting solution.
