Storage/Staging: Manufacturer saves 85% in lighting energy with intelligent LED system

Connected lighting system includes web-based portal for performance metrics and configuration.
By Josh Bond, Associate Editor
October 02, 2013 - MMH Editorial

The Westerville, Ohio management team of Worthington Cylinders, the world’s leading global manufacturer of pressure cylinders and tanks, was looking to upgrade its lighting system but knew the additional expense must be justified. After installing an intelligent LED lighting system, the company now saves more than a million kWh of energy each year, cutting energy costs by 85%.

Before the upgrade, the 177,000-square-foot facility relied on a series of aging 400- and 600-watt high-intensity discharge (HID) and high-pressure sodium (HPS) bulbs. The management team was concerned with both energy costs and the high maintenance burden associated with traditional industrial lighting.

Because oversized machinery is closely positioned within much of the production space, frequent re-lamping and re-ballasting of the old lighting fixtures was highly disruptive to the facility’s 24/7 manufacturing operations. The team, lead by plant engineering project manager Fred Timm, initially evaluated a series of basic LEDs with add-on sensors separately mounted throughout the facility. However, the projected energy savings did not justify the expense.

Instead, the team selected LEDs paired with a lighting control system. “We were looking for more than just incremental energy efficiency improvements; we wanted major savings that for the lifetime of the installation,” says Timm. “The new system enabled us to accomplish that goal with maintenance-free fixtures, better, higher quality light to facilitate our operations, and the ability to control how we use lighting and adjust settings as needed.”

The new low-wattage LED fixtures feature integrated occupancy and daylight sensing, power metering and wireless networking. The web-based lighting management software provides access to all lighting performance metrics and a simple interface for making adjustments.

Today, the facility is saving more than 85% in annual lighting costs while providing managers with control over how lighting is used within their facility. The system leverages available daylight where possible and eliminates costly and disruptive re-lamping and re-ballasting exercises. Together, these savings are on track to produce a return on investment within three years.

Digital Lumens
617-723-1200
http://www.digitallumens.com



About the Author

image
Josh Bond
Associate Editor

Josh Bond is an associate editor to Modern. Josh was formerly Modern’s lift truck columnist and contributing editor, has a degree in Journalism from Keene State College and has studied business management at Franklin Pierce.


Subscribe to Logistics Management magazine

Subscribe today. It's FREE!
Get timely insider information that you can use to better manage your
entire logistics operation.
Start your FREE subscription today!

Recent Entries

Transportation and logistics bellwether UPS began 2015 in solid fashion with first quarter revenue up 1.4 percent at $14.0 billion and operating profit up 11 percent at $1.7 billion. Earnings per share were up 14 percent at $1.12, which exceeded Wall Street expectations of $1.09, while revenue was shy of the Street’s $14.27 billion estimate.

Last week, the United States Department of Transportation took further steps to address various issues identified in recent train accidents involving crude oil and ethanol shipped by rail. The announcement was made by DOT with other DOT agencies, including the Federal Railroad Administration (FRA) and the Pipeline and Hazardous Materials Safety Administration (PHMSA).

Logistics Management Group News Editor Jeff Berman had an opportunity to interview Derek Leathers, President and Chief Operating Officer of Werner Enterprises, at this month's NASSTRAC Shippers Conference and Transportation Expo in Orlando. They discussed various aspects of the truckload market, including prices, fuel, and regulations.

During this webcast our presenters will apply the findings of the 23rd Annual Trends & Issues in Transportation and Logistics Study to the world of shipper-carrier decision making. They'll examine the primary aspects that will influence the future direction for shipper-carrier decision-making.

For February, the month for which most recent data is available, the SCI dropped to -1.0 from January’s 2.6, with FTR explaining that the short term positive impact from one-time adjustments for rapidly dropping diesel prices and the suspension of the 2013 motor carriers hours-of-service expires later this year.

About the Author

Josh Bond, Associate Editor
Josh Bond is an associate editor to Modern. Josh was formerly Modern’s lift truck columnist and contributing editor, has a degree in Journalism from Keene State College and has studied business management at Franklin Pierce. Contact Josh Bond

Comments

Post a comment
Commenting is not available in this channel entry.