Coca-Cola Bottlers (Malaysia) Sdn Bhd – LED High-Bay Lighting Replacement
Rope-Access Replacement of 645 High-Bay Lights Above an Active Production Area
Replacing lighting inside an industrial facility can be particularly challenging when the fixtures are positioned at significant heights above valuable production machinery. At Coca-Cola Bottlers (Malaysia) Sdn Bhd, the project involved replacing 645 existing light fixtures with energy-efficient UFO LED high-bay lights at working heights of up to approximately 20 metres.
The lighting points were located above production machinery, making conventional access methods impractical. Scaffolding could not be erected without occupying a large amount of floor space and potentially affecting the equipment below. Mobile elevated work platforms and other access machines were also unsuitable because of restricted floor access and the arrangement of the production lines.
To complete the replacement safely and efficiently, Vertical Pro used a specialised rope-access system to reach every designated lighting point.
A Challenging Industrial Working Environment
Industrial lighting replacement involves more than removing an old lamp and installing a new fixture. The team must carefully manage height, access restrictions, electrical safety, tools and equipment while protecting the operational areas beneath the work zone.
For this project, the presence of production machinery directly below the lighting fixtures was a primary consideration. Any uncontrolled movement or dropped object could damage valuable equipment, create a safety risk or interrupt production.
Before work commenced, each section was assessed to determine the most suitable rope-access position, anchorage arrangement and replacement sequence. The lighting points were then organised into manageable work zones so the team could progress systematically through the facility.
Close coordination with the relevant site personnel was also essential. Work schedules, access restrictions, electrical isolation requirements and controlled areas had to be considered before technicians entered each section.
Rope Access Without Scaffolding or Access Machines
Rope access provided an effective solution for reaching lighting fixtures in areas where scaffolding and mechanical access equipment could not be used. Instead of occupying the production floor with large structures or machinery, trained technicians accessed the work locations using ropes, harnesses and approved work-at-height equipment.
This method significantly reduced the amount of floor space required for access. It also allowed technicians to move between elevated work positions while avoiding direct contact with the production machinery below.
Every working area required an appropriate access and rescue plan. Rope systems, connectors and personal protective equipment were checked before use, while tools and replacement components were secured to prevent them from falling.
A controlled exclusion zone was established beneath each active work location wherever required. These precautions helped protect site personnel, machinery and surrounding property throughout the replacement process.
Replacing 645 Fixtures with UFO LED High-Bay Lights
The project covered a total of 645 lighting units. The existing fixtures were removed and replaced with UFO LED high-bay lights designed for large industrial spaces with high ceilings.
Each replacement had to be handled carefully at height. The technicians secured their tools and components before disconnecting and removing the existing fixture. The new LED high-bay light was then positioned, installed and checked according to the agreed work procedure.
Electrical isolation and related electrical work were coordinated with authorised personnel to ensure the lighting circuits were safe before replacement activities began. Once a section was completed, the newly installed fixtures could be inspected and function-tested before the team progressed to the next work zone.
Working through the facility in a structured sequence helped maintain quality and ensured that all 645 lighting points were properly accounted for.
Improving Industrial Lighting Performance
UFO LED high-bay lights are well suited to factories, warehouses and other facilities with elevated ceilings. Compared with older conventional lighting, LED fixtures can provide efficient illumination while requiring less frequent replacement.
Improved lighting can support visibility across production areas, walkways and workstations. It may also help create a safer and more comfortable environment for employees performing detailed tasks or operating equipment.
The extended service life associated with LED technology is especially valuable when fixtures are installed up to 20 metres above the floor. Reducing the frequency of lamp replacement can minimise future work-at-height activities and the operational planning required for maintenance.
Specialised Solutions for Inaccessible Work Areas
The successful replacement of 645 high-bay fixtures demonstrates how rope access can solve complex maintenance challenges in industrial environments. It enabled technicians to reach difficult locations above production machinery without relying on scaffolding or access machines.
Vertical Pro provides professional rope-access solutions for lighting replacement, inspection, cleaning and maintenance in factories, warehouses and high-rise properties. Every project is planned according to the site conditions, access limitations and safety requirements.
When conventional access is not possible, our rope-access team can develop a practical solution for your facility. Contact Vertical Pro today to discuss your industrial work-at-height requirements and request a customised quotation.
