$3.6 million in projected ten-year savings. A 75% cut in power draw. Zero fluorescent tubes left to damage, misuse or replace. When a men's correctional facility in Auckland retrofitted its in-cell lighting with NexaLux™, these were the results, turning a costly, high-risk problem into a genuine safety and efficiency win.
The Challenge
Correctional facilities place enormous demands on in-cell lighting. Fittings need to withstand deliberate damage, support routine safety checks, and keep running reliably night after night.
At this Auckland facility, standard fluorescent fittings were proving a serious liability. Between January and June 2024 alone, 190 light fittings were damaged and replaced, at an average cost of $1,200 each. That's over $220,000 spent on repairs in six months.
The damage wasn't just costly. Fluorescent tubes were being used as makeshift weapons, smoking devices and tools for self-harm. The custom-made diffusers protecting them, imported at roughly $900 each, were often slow to source, leaving fittings out of action for extended periods.
The Solution
The facility replaced its fluorescent fittings with NexaLux™, an advanced LED lighting solution built on our proprietary NexaGlaze™ optical composite technology.
The optical composite cover is fully transparent, so officers can see every internal component at a glance, which itself deters tampering. It is also impact-resistant, reported as 40 times stronger than glass and 30% clearer, giving a genuinely vandal-resistant barrier without sacrificing light quality.
Key features of the retrofit:
Fluorescent tubes eliminated entirely, removing a known self-harm and smoking risk
Tamper-proof rivets, secure electrical connections and a tamper-resistant mounting system
Same footprint and anchor points as the original fittings, using six dynamic bolts, four optical mounting bolts and two electrical connections
LED strips mounted on an aluminium heat sink for reliable thermal management
Because the new units matched the existing footprint, installation was quick, with no cosmetic repairs or repainting required, and minimal disruption to the wing.
The Results
The figures below are drawn from the facility's own case study data, tracked via monthly load usage and BMS records since December 2023.
Cost savings
Initial purchase of 950 units: approximately $772,302, compared with $1,140,000 for competitor lighting
Projected ten-year savings: over $3.6 million
Energy Efficiency
Up to 75% less power draw per unit (30W versus 81W for the previous fluorescent fittings)
Around 80% greater energy efficiency overall
Annual energy cost savings of $25,666.80
Durability and maintenance
Lifespan of 50,000 to 80,000 hours, equivalent to 11 to 18 years at 12 hours' use a day
Maintenance required only once in ten years, with no ballasts or tube failures to manage
Extended warranty and lifetime cover on the base plate and optical composite, subject to conditions
Safety and wellbeing
Removal of fluorescent tubes eliminates a recognised self-harm and misuse risk
Transparent optical composite cover supports faster, clearer welfare checks
The project also created employment opportunities for prisoners involved in the works, supporting purposeful activity within the facility
Why It Matters
This project shows what NexaLux™ and NexaGlaze™ can do in one of the toughest environments there is. If a lighting system can hold up in a correctional facility, cut six-figure repair bills and materially improve safety, it's a strong indicator of how it will perform in any high-demand commercial or public setting.
Partner with Advanced Materials Experts
From initial risk assessment to certified product supply, the NexaGlaze™ team provides advanced materials engineering to secure your facility or high risk public space.
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