Closing the loop – and extending the lifecycle of luminaires
The concept of rebuilding old luminaires to save material and energy is growing. Sometimes, all an outdated luminaire needs to shine bright again is some tender love and engineering skills. We met Emma Hallman, Mathilda Holl and Andreas Ekslätt, the team behind ReLight at Fagerhult, to discuss the challenges of finding solutions that will take old luminaires into the future.
At Fagerhult, a deeply rooted innovation culture influences all aspects of work. Possibly, it springs from the founder Bertil Svensson's mindset of solving problems with sometimes small means – and curiosity and dedication. Unlike today, sustainability may not have been a buzzword back then. However, using our resources consciously and striving for high quality have always been cornerstones for Fagerhult. Today, a new focus on circularity has urged us to challenge our thinking and makes us conscious of finding long-lasting solutions.
Fagerhult's Bespoke Lighting Solutions (BLS) department has developed unique luminaires and adapted solutions for many years. So, refurbishing and updating old luminaires is something familiar to us. However, the ambition to reuse and rebuild old luminaires to lower climate impact has increased over time. In this process, yesterday's design and technology are brought up to speed by today's advances to meet the requirements of tomorrow.
"We want to make reusing luminaires a more accessible choice. We have complete standard kits for many luminaires to be ordered more or less off-the-shelf. We thoroughly analyze new requests and design solutions based on our core ideas of light comfort and high quality. We are constantly refining our process, with a desire to facilitate reuse as much as possible." Emma Hallman, Business Development Manager
ReLight your old luminaires
To the ReLight team at Fagerhult, there are no unusual questions or impossible solutions. Daily, they manage inquiries regarding specially developed lighting solutions for projects from Fagerhult's markets. It's a complex process, but over time, they have learnt that some projects are ideal for reusing old luminaires instead of investing in new ones.
"To us, the luminaire's qualities in lighting comfort, safety and aesthetics are at the core of every ReLight project. When requested, we also calculate if – and how much – we can reduce the luminaire's total climate impact through its lifecycle." says Emma Hallman.
Within ReLight, there is an outspoken will to save materials and energy – and make an environmental effort by updating the luminaires. However, not all old luminaires can live forever; some are outdated and better recycled than refurbished.
"If the circumstances don't meet our requirements and it doesn't work to rebuild the luminaire, we will not take the project further. We would never compromise on light comfort, quality, safety or the expression of the luminaire if it does not result in a first-class end solution", says Emma Hallman.
At Fagerhult, safety and quality are the red threads that combine all products. And ReLight is no exception. Throughout the process, CE-marking and testing are crucial factors.
"To ensure the overall quality, the updated luminaire is CE-marked in full before delivery. We also want to make the installation on site both smooth and quick, and the new kit is as close to a complete luminaire as possible," says Andreas Ekslätt, Design Engineer.
TEXT LINDA KARLSSON
PHOTO BJÖRN CEDER
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Reused printing plates in Fagerhult’s new cardboard luminaires
A used printing plate can be given a new lease of life as a component in a luminaire. This is exactly what happens in the Wrapped corner and ceiling luminaires, where used printing plates are reused and become an integral part of the design. Reusing printing plates perfectly encapsulates the concept of industrial symbiosis – where a residual product from one operation becomes a valuable input product in another. The idea took shape at a kitchen table in Lund, when Fagerhult’s Sustainability Manager, Niclas Thulin, was visiting his parents.“They asked how things were going at work, and I told them about Kvisten, which we were in the final stages of at the time. We were reusing reflectors from old TV sets for that product, and I mentioned that we were looking for more residual materials to reuse.” Niclas went on to explain that the company needed a steady flow and consistent quality over time – and, ideally, the same format as well. “And then my Dad, who’s worked in the printing industry his whole life, suddenly says, ‘What the heck, we’ve got loads of printing plates. They’re of the highest quality, always the same format – and they’re recycled.’ The next day, he brought home a couple of printing plates, which I then took to work and gave to my colleagues in the development department. “I could tell right away that they were similar to the materials we use in many of our luminaires. In addition, there were a large number of them, the quality was high and consistent, and they were roughly the same size. All the qualities we were looking for were there.” Quote Niclas From printing works to luminaire When the printing plates arrived at Fagerhult’s development department, they quickly attracted a lot of interest – could they be used in the new Wrapped luminaires?“I was in touch with the printing works about Wrapped and how we could use paper for the actual luminaire body. The printing plates were in the back of my mind at the time, so I raised the issue with them. They jumped at it immediately,” says Jonathan Levinsson, Design Engineer at Fagerhult.The printing works uses a great many printing plates, and some of these are now being used for Wrapped Corner and Wrapped Surface (ceiling). The sheet metal is installed on the inside, as part of the structure. Here it contributes to electrical safety, for example, by acting as an insulation and earthing layer. It also provides stability and can be used to secure cables and other components, for instance. Circular flow. Waste from one industry creates value in another. “The fact that the plates maintain the same dimensions and specifications over time ensures a stable material flow and makes it possible to plan production. This is a major advantage for us,” says Jonathan. Start with the material – not the product The work also highlights an important principle when it comes to industrial symbiosis. It is often easier to find a use for a residual product than to first decide what product you want to make and then try to find suitable recycled material.“I think you have to start with the raw material and then design the component based on that. If you design a component first and then try to find a suitable material, it can be really difficult,” says Niclas.The printing plates are a clear example. If Fagerhult had instead started by asking itself, ‘Where can we find sheet metal as a residual product?’ the search would probably have focused on the metal industry.“We might have been looking for a business that bends or punches sheet metal. We would never have thought about printing works, which are a completely different kind of business. That’s what makes industrial symbiosis so interesting.”At the same time, finding new connections is not easy.“It’s hard to know what residual products other businesses have, especially when you don’t always know exactly what you’re looking for yourself. I think we need more forums where people can gain an insight into other industries and businesses, and where we can discuss industrial symbiosis with a more open mind,” says Niclas. By sharing and developing ideas, Niclas and Jonathan enable new and innovative collaborations. Ideas that roam between departments At Fagerhult, there is already a way of working that fosters this kind of exchange of ideas. Niclas and Jonathan continually bounce ideas off each other, and a small group of people from Sustainability and R&D meet from time to time in order to brainstorm new ideas.“We share a lot of ideas with each other. It’s fun to see what grabs Jonathan’s interest and what doesn’t. At times, someone will have stumbled upon something that we can then build on,” says Niclas.In the case of the printing plates, the solution came from an unexpected source.“It was really just luck. My Dad wasn’t sitting around wondering how he could solve a problem for Fagerhult. But when I told him what we needed, he saw the opportunity right away. He’s clever and often comes up with his own solutions,” says Niclas. “I’m almost a little annoyed that I didn’t think of it myself.” A solution that links multiple workflows So far, we have not performed any calculations regarding the exact climate benefits. The principle is clear, however: when existing materials can be used rather than virgin raw materials, the potential exists to reduce the need for new resources. “We need to be open throughout the entire chain and to dare to look beyond our own industry. The right materials might be found in a place we’d never even have thought of looking,” concludes Niclas Thulin.
Fagerhult halves CO₂ emissions – 49% reduction since 2021
Material choices, product innovations, reuse initiatives, and a systematic analytical approach underpin Fagerhult’s reduced climate impact. Over five years, total CO₂ emissions have decreased by 49 per cent – far exceeding the company’s own targets. Using resources wisely has been a cornerstone throughout Fagerhult’s 80-year history, and it continues to shape the business today. Since 2021, this work has gained even sharper focus and direction, with clear carbon-emission targets, long-term plans, and a comprehensive sustainability programme based on life-cycle assessments (LCA).“A reduction of this magnitude in such a short time shows that systematic work truly makes a difference. It is the result of many large – and small – initiatives, where every improvement contributes to the whole,” says Josefin Carlsson, Sustainability Specialist at Fagerhult. Fagerhult's total CO₂ emissions have decreased by 49 per cent compared to 2021 levels. Many initiatives – one shared direction The success is underpinned by a series of strategic decisions in product development and processes. The work has been carried out across several parallel tracks, following the principle many small streams together create significant impact.“Innovation and sustainable solutions make a real difference for our customers and reduce emissions across the entire value chain – not just in our own production,” adds Josefin Carlsson. Josefin Carlsson, Sustainability Specialist at Fagerhult, Habo. The greatest impact is in the use phase, where emissions since 2021 have been steadily reduced by around 200,000 tonnes of CO₂e – a 49 per cent decrease. At the same time, emissions in Scope 1 and 2 have been reduced by 60 per cent compared with the base year. Sustainability in practice A decisive factor behind this progress is the many parallel initiatives, with material choices playing a central role.Since 2025, the majority of luminaires with housings made from extruded aluminium profiles contain up to 75 per cent recycled material. This contributes to an annual climate saving of approximately 225 tonnes of CO₂e.In 2025, Fagerhult reused more than one hundred luminaires per working day through the ReLight initiative. By upgrading existing luminaires with new technology and extending their life cycle, the climate impact from materials and production is significantly reduced. In total, more than 50,000 products have been given a new lease of life through reuse.Product development is also a key driver of the transition, and several innovations have both reduced climate impact and increased energy efficiency: Multilume Re:Think has reduced Scope 3 emissions by over 320 tonnes of CO₂e through smart design and environmentally sustainable material choices since its launch in 2021. This is equivalent to planting and growing 1,300 trees for ten years. Twin Dual Driver has reduced the climate impact of control gear by 49 per cent through more efficient electronics and improved material composition. Wrapped’s Solid Board housing has up to 89 per cent lower climate impact per kilogram compared with virgin aluminium. Gallery - products At the same time, more than one in ten luminaires sold today includes an integrated sensor, helping to reduce energy consumption during operation. A key factor behind the success is the long-term, fact-based approach.“Based on life cycle assessments, we have identified where and when climate impact occurs – and which actions have the greatest impact. We’re now carrying that knowledge forward in our continued efforts to further reduce our climate impact,” concludes Josefin Carlsson.