LED Lighting Retrofit by GLT at Hydro Uphusen
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GLT TUBE Count381
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Annual power savings250,000 kWh
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Annual operation hours4,004 h
The Challenge
At the Uphusen plant, the existing lighting system relied on conventional T5 and T8 fluorescent tubes, which led to high energy consumption and frequent maintenance. Hydro sought a solution that would reduce energy use, extend service life, and align with its sustainability strategy — without costly structural modifications or production downtime.
The Solution – LED Retrofit with GLT LED TUBE and GLT High Bay
A total of 381 old T5 and T8 fluorescent tubes were replaced with GLT LED TUBES in a 1:1 retrofit process according to IEC/EN 62776, carried out during ongoing production. The aluminum housing of the GLT LED TUBE is made from Hydro REDUXA, a low-carbon, sustainable aluminum with a particularly small CO₂ footprint.
The existing luminaires were converted according to EN standards, and the old ballasts were removed. The LED driver is fully integrated into the GLT LED TUBE, allowing non-electrical personnel to easily replace the light source in the future. Maintenance costs are reduced to an absolute minimum, supported by the exceptionally long service life of up to 130,000 hours.
In addition, 120 HQL lamps were upgraded to GLT High Bays – also implemented as a 1:1 retrofit solution without any production downtime.
The new LED lighting system meets all technical standards and legal requirements for quality, energy efficiency, and sustainability. Thanks to the Environmental Product Declaration (EPD) of the GLT LED TUBE, the environmental impact of the lighting can be transparently measured and documented.
Key advantages of our LED retrofit for Hydro Uphusen:
- Energy-efficient and cost-effective: 381 GLT LED TUBES save around 250,000 kWh of electricity per year.
- Maintenance-free and long-lasting: The LED retrofit solution with GLT LED TUBES minimizes maintenance requirements thanks to their 130,000-hour lifetime.
- Sustainable and resource-efficient: The scientifically verified life cycle assessment (EPD) of the GLT LED TUBE is an essential component of Hydro’s sustainability and ESG strategy.
- GLT Reuse System: At the end of their service life or rental period, GLT LED TUBES are returned, refurbished, or recycled. When purchasing new GLT TUBES, we take back the old ones and credit €5 per unit.
Key Benefits & Advantages
130,000 hours
service life
(L70)
1:1 replacement
without modification
(IEC EN 62776)
Nearly
maintenance-free
LED lighting
Scientifically
EPD verified
and ESG compliant
Conclusion
By switching to GLT LED TUBEGLT LED TUBE and GLT High BAYGLT High BAY from German LED Tech, Hydro Extrusion is setting a clear example for energy efficiency and sustainable resource use. The project demonstrates how industrial companies can reduce energy costs and environmental impact through state-of-the-art retrofit technology.
A particularly noteworthy aspect: the collaboration between Hydro and German LED Tech closes the sustainability loop — the GLT LED TUBE housings are made from Hydro REDUXA aluminum, produced at Hydro’s own Achim facility. This combination of innovative technology and responsible material sourcing earned German LED Tech the Hydro CO₂ Award 2024.
Customer Testimonial
“By upgrading to LED lighting from German LED Tech, we have not only improved our energy efficiency but also taken our sustainability efforts to the next level. We are particularly proud that the GLT LED TUBES are made with our CO₂-reduced Hydro REDUXA aluminum – a perfect example of circular economy and true partnership in action.”
Hydro Deutschland
Learn more about the LED products used –
GLT LED TUBE++ and GLT High Bay
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