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 ·

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

About the Author

Josh Bond, Senior Editor
Josh Bond is Senior Editor for Modern, and was formerly Modern’s lift truck columnist and associate editor. He has a degree in Journalism from Keene State College and has studied business management at Franklin Pierce University.

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!

Article Topics

All Topics
Latest Whitepaper
Warehouse Management Systems (WMS) / Inventory Management Technology: 6 Trends for the Modern Age
Here’s how the next generation of warehouse and inventory management systems are evolving to help logistics operations operate more efficiently and improve their bottom lines in our brave, new digital age.
Download Today!
From the March 2018 Logistics Management Magazine Issue
We know e-commerce is reshaping logistics, but what are the technologies savvy managers can leverage to meet evolving requirements and shifting operational constraints? We’ve rounded up insights from leading analysts to share tools that are available now as well as what’s on the horizon.
Reverse Logistics in the “Age of Entitlement”
Logistics Management’s Viewpoint on E-commerce: Leveraging available tools
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly email newsletter!
Latest Webcast
Securing IoT data across the connected supply chain
Learn why a holistic approach to IAM is the most effective way to govern access to your systems and information requested by your partners, vendors, customers, and connected devices.
Register Today!
Evolution of E-commerce: The possibilities of tomorrow
We know e-commerce is reshaping logistics, but what are the technologies savvy managers can leverage...
State of Global Logistics: Delivering above and beyond
Industry experts agree that costs across all sectors worldwide will continue to rise in 2018, and...

2018 Rate Outlook: Economic Expansion, Pushing Rates Skyward
Trade and transport analysts see rates rising across all modes in accordance with continued...
Building the NextGen Supply Chain: Keeping pace with the digital economy
Peerless Media’s 2017 Virtual Summit shows how creating a data-rich ecosystem can eliminate...