Vandalism Proof Solar Lighting

APC Technology is typically focused on designing and manufacturing solutions engineered to perform and survive in harsh & hazardous environments. Our partnership with Green Frog Systems required all of those skills but also has the added dimension of meeting vandal proof certifications.

Green Frog is a South Australian company with a global presence. Founded in 2011, the company ships high quality solar lighting and energy storage solutions for roads, pathways and other commercial and community applications worldwide.

The business challenge

Green Frog Systems were looking for a partner to bring to market a modular shelter light ideal for bus stop shelters, rest areas and public amenities. David Wilson CEO and founder of the business explained why he chose to work with APC Technology. “We started working with APC in 2012. We knew they had a solid reputation and the expertise to engineer equipment that would survive in extreme conditions. The original project involved ruggedising LED light fittings for use by Flinders Ranges Council and these are still in use today. ”

“So when we started to develop the concept of a modular shelter light to add to our range, we knew we needed to make sure the unit was built to last and designed to withstand the toughest environments so we naturally approached APC. ”

Project requirements

All products made by Green Frog Systems aim to meet a set of criteria:-

• Easy to install kit based concept
• Cost effective
• Vandal proof
• Water proof
• Bug and insect proof
• Extreme temperature ranges
• Reproducible design

APC Technology were engaged to engineer and manufacture the first production batch. The project included the design and manufacture of the metalwork, internal layout of the light box including the mounting of the GFS proprietary components; the design and manufacture of the housing and the ruggedisation of the solar panel.

At the root of the design was the need to meet the criteria set out by Green Frog. David commented on the project.

“During our initial discussions APC were made aware that once the unit went to mass market we would manufacture at our various global production cells. We really were engaging them for their proven skill set of being able to engineer equipment that can perform and survive against the elements. Additionally they had the in-house capability to prototype a range of components enabling robust testing prior to manufacture, as well as in-house thermal test facilities to ensure certification criteria were met.”

“Their expertise in the design phase and the open dialogue between our engineering departments meant changes were executed in a timely manner ensuring the project moved rapidly. From initial design to the first production run, the process took about 8 weeks. ”

The final manufactured units were engineered to meet a range of test standards including IP65 water resistant, IK10 vandal proof and UL certification. The work conducted at the early stages by APC meant when the application for the stringent UL standards was made for our USA operations it was a painless exercise.

Scott Begbie Managing Director at APC commented on the project. “The vandalism aspect is not a common issue we consider but with our proven track record in military grade equipment, we knew we would be able to take our knowledge and ensure the design not only performed against the elements but survived any attempts of property destruction. ”

On site feedback

The first set of units were sent to the Northern Territories. During the first year the design was tweaked based on feedback from the field. The engineering group at APC Technology and the team at Green Frog continued to work together to improve the design of the modular shelter light. For example the sealant of the unit was revised as some were infested with ants who nested resulting in the corrosion of internal components. The feedback on the mounting bracket also resulted in an additional redesign to optimise the ease of installation.

Within 18 months of the project starting the GFS-50-MSL modular shelter light was being massed produced and shipped around the world.

Contact Details | Green Frog Systems | greenfrogsystems.com.au | (08) 7200 3909