As part of its investment in production-line technology in the run-up to the launch of the new model, Vauxhall asked Cooper to come up with a new luminaire that would be capable of withstanding the particular demands of the car-manufacturing environment, while providing lighting levels ranging from 500 to 3000 lux.

Cooper's team of product design engineers immediately rose to the challenge and within very tight timescales produced initial designs for the new fitting - dubbed the Cheshire - which is a twin lamp 70W, totally enclosed luminaire with a toughened glass front panel and a quick-fit connector system.

Feedback from Vauxhall engineers resulted in a few slight modifications to the design to meet their precise requirements and the special luminaire went into production at Cooper's Doncaster factory soon afterwards.

The Cheshire luminaire features standard triphosphor T8 lamps, a high frequency ballast for maximum energy efficiency and a highly polished aluminium parabolic reflector.

The front of the luminaire's IP54 housing is hinged for easy access and incorporates a toughened glass panel to prevent damage from the sparks that fly off car bodies during the robotic manufacturing process.

Ease of maintenance is also a key issue for Vauxhall. The Cheshire was therefore designed with a quick-fit connector system that allows a complete luminaire to be replaced in the shortest possible time. Any maintenance work on the luminaire, even changing a lamp, can then be carried out without disrupting the production line.

In the final inspection areas a lighting level of 3000 lux is required. This was achieved by positioning the Cheshire luminaires at close spacings. Following extensive computer aided design calculations carried out by Cooper's experienced lighting design staff, luminaires were mounted both above and vertically to the sides of the production line.

In addition to the Cheshire fittings, Cooper has supplied Vauxhall's Ellesmere Port plant with nearly a thousand Pacemaker 400W high bay luminaires, a thousand Crompack batten luminaires fitted with special reflectors, hundreds of Tufflite IP65 sealed fluorescent luminaires and a wide variety of emergency lighting products.

The main reception area of Hooton House, located on the same plant, has benefited from the installation of Crompton Aeroform and Solstar luminaires, providing a high quality, evenly illuminated environment. In the office areas, Intellect Digital Moducell luminaires have provided effective illumination of the working space, with the benefit of greatly improved energy efficiency as a result if the integrated lighting controls.

Exterior locations have seen the installation of Crompton Strada and Churchouse Bollard luminaires, safely illuminating footpaths, piazza and car parking areas.