A high-throughput bottling plant in need of leaner, brighter illumination.
Lotte Akhtar Beverages (Pvt) Ltd. is the authorised Pepsi Cola bottler for Lahore, running multi-shift production lines that depend on consistent, bright lighting for quality control and workforce safety. In March 2024, Crest LED retired its aging Philips fluorescent system, 150 fixtures running at 120W each, and deployed a high-efficiency LED Tri-Proof platform in its place.
An aging fluorescent system drawing 18 kW, with too little light to show for it.
The plant was operating on a Philips fluorescent setup that had quietly become a growing liability. 150 tubes running at 120W each drew 18,000W in total, generating monthly electricity bills above PKR 1.17 million while delivering inadequate brightness, excess heat, and a steady stream of maintenance interruptions.
The new Crest LED lighting has completely transformed our production floor. It is noticeably brighter, the heat has virtually been eliminated, and our electricity bill has been cut in half. The maintenance team practically has nothing left to replace.
A 1-for-1 retrofit engineered to halve power draw without compromising uptime.
Crest LED conducted a detailed assessment of the facility before designing a tailored plan. The objective was direct: match every existing fluorescent fixture with a high-efficiency LED equivalent that would cut energy in half while dramatically improving light quality.
We specified 150 units of the Crest LED Tri-Proof CR-T8-T60W-TPS, a 60W industrial-grade luminaire purpose-built for demanding manufacturing environments. These replaced the 120W Philips fluorescents on a 1-for-1 basis, instantly halving the total power draw from 18,000W to 9,000W.
The Tri-Proof design ensures resistance to dust, humidity, and vibration, ideal for an active bottling plant, while delivering a flicker-free, high-lux output that transformed the working environment from day one.
Payback in 18 months, measurable returns from the first billing cycle.
A line-by-line financial model was prepared for the project. The charts below visualise the magnitude of change in power draw and monthly cost, both halved on a 1-for-1 fixture replacement basis.
From 18,000W to 9,000W of total draw.
A direct halving of facility-wide lighting load, achieved without altering fixture count or layout.
From PKR 1,170,000 to PKR 585,000 / month.
Savings compound month-on-month, fully recovering the installation investment inside 18 months.
Full parameter comparison, every metric improved.
| //Parameter | //Before · Fluorescent | //After · Crest LED |
|---|---|---|
| Power consumption | 18,000 W | ↘9,000 W |
| Monthly electricity cost | PKR 1,170,000 | ↘PKR 585,000 |
| Brightness level | 150 Lux | ↗280 Lux |
| Heat generation | 50% | ↘< 5% |
| Maintenance frequency | 10% | ↘< 1% |
Outcomes the plant can see, feel, and bank.
The transformation arrived in the first billing cycle and has compounded every month since. Below: headline outcomes and the secondary metrics that quietly matter.
