Tokio Marine - St Botolph

As part of the comprehensive 6th Floor refurbishment, Tokio Marine sought to explore sustainable circular-economy solutions by remanufacturing their existing 600mm x 600mm luminaires. To achieve this, The Regen Initiative was invited to collaborate on the project. The primary objective was to deliver upgrade options that could be executed seamlessly on-site with minimal operational disruption.

The Challenge

The existing lighting system featured 600 x 600mm Mellowlight 4 T5 luminaires that were highly inefficient and required an upgrade to modern LED technology. The primary objective was to find a sustainable solution that would minimise both material waste and operational downtime.

The Solution
Following a thorough technical evaluation, the team engineered a bespoke, plug-and-play LED geartray conversion kit. Instead of replacing the entire luminaire body, this custom geartray was designed to fit directly into the existing Mellowlight 4 housing.

This innovative approach delivered several key advantages:

  • Rapid Installation: The geartray allowed for a quick, "drop-in" installation on site, significantly reducing labour time per fitting.
  • Minimal Disruption: The seamless installation process ensured that day-to-day operations in the building could continue with virtually zero downtime.
  • Cost & Waste Reduction: By reusing the existing luminaire carcases, the project drastically cut down on material disposal costs and aligned perfectly with circular economy principles.
  • Enhanced Performance: The new LED components vastly improved energy efficiency, reduced maintenance intervals, and delivered superior light quality.

Luminaire conversion

The new LED geartray is centrally integrated into the exact position of the original fluorescent lamps. This precise placement ensures an seamless architectural retrofit while delivering identical illumination, lumen output, and light distribution characteristics. By matching the original optical footprint, the upgrade maintains visual consistency across the space without requiring layout redesigns.

Drawing Design

This drawing specification outlines the requirements for a high-performance retrofit LED gear tray designed to replace obsolete internal components within existing luminaire housings. The system features high-efficiency Tridonic 4000K LED modules, a remote Tridonic DALI-addressable driver, and an optional integrated emergency lighting package (Type Ae), ensuring a sustainable, uniform, and low-maintenance lighting upgrade.

3D Visualisation

To ensure the geartray design aligned perfectly with the client’s expectations, our team developed and presented a comprehensive 3D visualisation. This presentation went beyond aesthetics, incorporating critical technical data—such as photometric details and anticipated lumen output—to verify both the visual integration and performance metrics prior to manufacturing.

Project Performance Metrics

  • 18,264 kg/CO₂e Avoided
  • 51% carbon avoidance in remanufacture
  • 284 Luminaires remanufactured
  • 47% Energy Savings across the project
  • In-situ LED retrofit of T5 fluorescent to LED 
  • On site installation Light levels maintained
  • Every retrofit gear tray tested and warranted