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Plants Cardinal Glass

Cardinal Glass promotes job acuracy
with Holophane lighting

Job accuracy was the main consideration when Cardinal Glass illuminated its new 150,000-square-foot plant in Fremont, Indiana. The facility purchases plate glass, cuts it to customer specifications, tempers and assembles the glass into thermal panes for shipment to major window manufacturers.

Because of the precise tasks involved, design-build contractor Bill Geiger, president, Clear Lake Electric, Inc., Fremont, designed the lighting system for the specific jobs performed.

“We considered first the building layout and the location of the production equipment, then we positioned the light fixtures to supply maximum visibility,” said Geiger. “The goal was to provide as uniformly lit environment as possible for employees working within the various areas.”

The lighting system installed is a combination of prismatic glass and fluorescent fixtures from Holophane Corporation and its Metal Optics subsidiary. Geiger indicated the glass luminaires are arranged in a uniform checkerboard pattern—rather than a grid—to place the light precisely where it is needed. This unique pattern also reduced the number of fixtures required by about eight percent as compared to a more conventional grid pattern. Holophane’s Computer Aided Lighting Analysis (CALA) software was utilized to help confirm fixture placement.

Prismalume® luminaires with 1,000-watt metal halide lamps are installed in high bay manufacturing areas where glass is tempered and stored. A total of 118 fixtures are mounted at 20 feet throughout the (size)-square-foot area—although the painted white metal deck ceiling ranges from 31 feet at the peak to 25 feet at the eaves. Fixtures are arranged in a checkerboard pattern, spaced at 35 feet lengthwise and 24 feet on the diagonal. Illumination levels range from 70 to 80 footcandles.

In particularly high production areas, luminaires are located more closely together to boost light levels. Fixture spacing is 35 feet lengthwise and 20 feet on the diagonal, with light levels generally 10 footcandles higher (80 to 90 footcandles). Luminaires throughout the high bay area are arranged around any storage racks, which are 18 feet high.

Besides the main production areas, Prismalume units with 400-watt metal halide lamps illuminate shipping and warehouse areas, including loading docks. Again, fixtures are arranged in a checkerboard pattern, spaced 35 feet lengthwise and 30 feet on the diagonal. The spacing is somewhat greater in this area because the light levels required are lower. Mounting height is 20 feet, with fixtures placed high enough to accommodate forklifts used to pick and move products. Light levels are 70 footcandles.

Holophane PrismGlo® Athena™ luminaires with 400-watt metal halide lamps illuminate the upper level of a 400’ x 200’ mezzanine, where metal is cut for the thermal panes. The PrismGlo units light the glass production room, maintenance area and dunnage room.

According to Geiger, the PrismGlo units were specified because of the lower ceiling height— which is 14 feet—and their 40 percent uplight component.

“The PrismGlo luminaires provide a glow that would not have been possible with fluorescent fixtures that supply 100 percent downlight. The illumination is very even because nearly half of the light is reflected off the ceiling,” Geiger said.

A total of 80 PrismGlo fixtures are installed above the upper mezzanine, mounted at 13 feet and spaced 20’ x 20’ apart. Illumination levels are 85 to 95 footcandles.

On the lower mezzanine, SS Series Specialty Industrial fluorescent fixtures from Metal Optics illuminate an assembly area and glass inspection line. The fluorescent units are mounted tightly against the bar joist ceiling at 10 feet. Conveyors are located four feet above the concrete floor.

“The fluorescent luminaires were selected because they provide 100 percent downlight. The high intensity illumination allows inspectors to detect any imperfections in the glass,” Geiger said. Illumination levels are 80 footcandles.

One hundred eight-foot fluorescent fixtures are installed above the lower mezzanine. Because the units utilize the efficient T-8 lamps (three per fixture) and Metal Optic’s energy saving ballast, energy requirements have been cut by 50 percent. The number of fixtures utilized is also 40 percent less than would have been required with other fluorescent systems.

Two Holophane Petrolux® II luminaires with 400-watt metal halide lamps are installed in the battery room where the tow motor battery banks are stored. The Petrolux II units are used here because they are rated for hazardous locations.

“We feel the Holophane systems are high quality and have met our specific requirements in each area,” said Geiger. “Perhaps the best testimony of the project’s success is the fact that Holophane luminaires have been installed in two additional Cardinal Glass manufacturing facilities. When representatives from the other locations saw how bright and clean the Fremont plant appeared, they wanted the same fixtures installed at their facilities.”

The luminaires at the Fremont facility are illuminated during two shifts each week. A switch with contactors controls them.

Cardinal Glass is headquartered in Milwaukee and operates 10 production facilities in the U.S. The company employs more than 2,000.


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