Thorn Lighting: Illuminating Sustainable Manufacturing Excellence

Thorn Lighting have been a successful and long standing name within the lighting industry, and recently, we have been recognised as a finalist in the Sustainable Manufacturing category at the prestigious The Manufacturer MX Awards 2024. For the past decade we have advanced our commitment to innovation and sustainability and our Spennymoor factory in County Durham is being celebrated for its efforts in creating a more sustainable future for the lighting industry.

Organised by The Manufacturer in partnership with the Institution of Mechanical Engineers (IMechE), The Manufacturer MX Awards (TMMX) are considered the gold standard for recognising excellence in manufacturing. With over 50 years of heritage, the awards shine a spotlight on businesses that lead the way in innovation, sustainability, leadership, and operational excellence, so we’re very excited to have reached the finals of the Sustainable Manufacturing category.

Established in the UK by Sir Jules Thorn in 1928, Thorn Lighting has grown from its humble beginnings to become a leader in sustainable lighting solutions. The company’s first factory, built in north London during the 1930s, marked the start of an illustrious journey in manufacturing luminaires. Today, Thorn operates a cutting-edge facility in Spennymoor, where over between 4,000 and 5,000 luminaires are produced daily.

This rich history of manufacturing excellence is upheld by a dedicated team of up to  400 employees, who operate as part of the global Zumtobel Group. With innovative systems, state-of-the-art equipment, and a focus on flexibility, Thorn’s Spennymoor factory can scale operations to meet demand while maintaining high standards of quality and efficiency.

At the heart of Thorn Lighting’s recognition lies its commitment to sustainability. The Spennymoor factory has implemented several initiatives aimed at reducing its carbon footprint, in line with its goal to achieve an 5% annual energy consumption reduction under the ISO 50001 Energy Management System.

Some of the key sustainable practices at Spennymoor include:

• Factory / Office lighting upgrade and including SMART controls saving over 1.1 million kWh electricity per year
• A further 1 million kWh of electricity savings through the installation of energy efficient air compressors and numerous other projects
• Paint plant oven size reduction, insulation improvement and eco burner installation saving over 1 million kWh gas per year
• Implementation of an Evaporation system which reduces waste to 90% distilled water, 10% sludge giving a reduction in hazardous waste of 225 tonnes per year.
• Reducing our site water consumption by 50% (1000 m3 of water per month) by recycling water within our paint plant process and measuring water cleanliness to reduce the frequency of tank cleans.

These measures are a testament to Thorn’s vision of balancing operational excellence with environmental responsibility. By embedding sustainability into its manufacturing processes, the company not only improves its own practices but also sets an example for the broader industry.

The Spennymoor facility is a hive of innovation and productivity. Featuring 37 multi-functional assembly lines, the site has the ability to switch between product families and specifications with minimal downtime. This adaptability allows for efficient production across a wide range of lighting solutions, catering to both indoor and outdoor applications.

Among its standout features are advanced technologies like:

• Laser Cutting and Injection Moulding: Ensuring precision and reducing material waste through efficient material utilisation of sheet steel and reprocessing of Polycarbonate within the moulding process.
• Intelligent Tools: Tools like screwdrivers that track torque and operation count to enhance quality and consistency.
• Icarts for Material Handling: These automated carts ensure smooth transportation of materials across the factory floor, boosting productivity and minimising delays.

Being named a finalist in The Manufacturer MX Awards is a proud moment for us here at Thorn Lighting, reaffirming its position as a leader in both sustainable lighting solutions and manufacturing excellence. The recognition highlights the importance of sustainability in modern manufacturing and showcases how companies like Thorn can lead the way in innovation without compromising environmental responsibility.

This achievement also reflects the resilience and ingenuity of the UK’s manufacturing sector, particularly as businesses continue to navigate challenges while driving positive change. Thorn Lighting’s success story serves as an inspiration for other manufacturers to embrace sustainable practices and innovate for a brighter, greener future.