Omnova Solutions is a global manufacturer of emulsion polymers, specialty chemicals and function and decorative surfaces headquartered in Beachwood, Ohio.
The low light levels at OMNOVA’s Green Bay, Wisconsin manufacturing facility were a safety concern for technicians maintaining and monitoring the facility’s processes.
The existing high pressure sodium light fixtures emitted a low level of visible light and rendered color poorly.
“The dim facility required our technicians to use flashlights to accurately do their work,” said OMNOVA Plant Electrician Zac Weiland. “Not having your hands free is a safety issue. And the color of the light was very yellow, which made it difficult to see the true color of objects like wire.”
Maintenance and replacement also proved to be a hassle. When the existing HID lights or ballasts failed, OMNOVA had to enlist the help of an outside contractor to erect a 25-foot scaffold to replace the fixtures. And since the plant runs 24/7, a burned-out fixture had the potential to cause a serious disruption in the evening and early morning shifts.
“The HID lamps last for about two to three years,” said Weiland. “But the main concern is the lamp depreciation. The lamp would start to burn out, then would eventually start randomly flickering on and off, and finally would fail. That’s when we’d change it.”
Most industrial facilities are tricky environments to work in due to pipes and other obstructions, but the OMNOVA plant is particularly hazardous. The plant is considered a Class I, Division II area where ignitable concentrations of flammable gases, vapors or liquids exist under normal operating conditions. This type of classification makes it even more difficult to find the right lighting solution.
HOW GRAYBAR HELPED
"It’s impressive to see the light levels now. It’s a night and day difference. The technicians are happy they no longer have to carry around flashlights to do their job." - Zac Weiland - OMNOVA Plant Electrician