Tyco International (NYSE: TYC) designs, sells, installs, and services security systems in the global commercial, industrial, retail, institutional, and government sectors. These systems detect intrusion, control access, and react to movement, fire, smoke, flooding, environmental conditions, industrial processes, and other hazards. As an environmentally conscious enterprise, Tyco has established a vision to implement the Zero Harm to People, Assets, and the Environment strategy.
Tyco was interested in identifying the benefits associated with LED lighting technology to reduce energy consumption and improve light quality within their Fire Protection manufacturing facility in Madison, AL. Tyco was assessing the viability of deploying LED lighting technology as a new standard for all its manufacturing facilities, and they selected this facility as a pilot for the project. Their objective was to use this project to render a proof of concept for both the cost savings and lighting quality objectives associated with the lighting system upgrade.
Eco Engineering’s audit revealed that across the production, office, and exterior work areas of this facility a total of 500 fixtures needed to be upgraded to LED technology. This included installing new LED high bay fixtures in the production area, LED retrofit kits for existing ceiling troffers in the office, and LED wall pack and pole lights across the exterior areas of the facility. We installed occupancy controls across the work areas to reduce the fixture operating hours during non-occupied periods.
The estimated life of the new LED system is 16 years in the production facility and 22 years in the office areas. The average light levels in the production areas increased from 21 foot candles to 32.7 foot candles following the upgrade.
- Forecasted Annual Demand Reductions:
605.76 kW per year
- Forecasted Annual Consumption Savings: 312,828 kWh per year
The lighting portion of the utility bill was reduced by 62% within the first year, and the project is expected to reach full payback within 3.6 years, well under Tyco’s payback time threshold for projects of this nature.
- Energy Savings within the First Year: >$45,000
Tyco was interested in identifying the benefits associated with LED lighting technology to reduce energy consumption and improve light quality within their Fire Protection manufacturing facility in Madison, AL.
Rolls-Royce doesn’t just design and manufacture cars. They are a global company that creates highly-efficient integrated power and propulsion solutions, predominantly used in aerospace, marine, energy, and off-highway applications. The Engine Services unit in Oakland, CA provides maintenance, repair, and support services for military customers using Rolls-Royce engines.
Recognized as a global leader in sustainability initiatives, Rolls-Royce has continuously focused on understanding energy use to identify inefficiencies and opportunities for improvement across all their business units. Their Engine Services division needed to upgrade their lighting system to one that would allow them to reduce their energy consumption and improve their productivity through higher quality lighting quality throughout their facility.
Eco Engineering began this project with an audit to identify and design the best lighting solutions to meet Rolls-Royce’s unique lighting needs. Specifically, Rolls-Royce needed to ensure that the lighting system could withstand the extreme wind, heat, and vibration characteristics of an engine testing facility. Additionally, Rolls-Royce required lighting for their office spaces. While this interior lighting system had less demanding requirements, the retrofitted LED system still needed to be outfitted with occupancy and motion controls to regulate and reduce unnecessary light output.
The primary components of this lighting retrofit involved removing T8 fluorescent fixtures that were hot, inefficient, and produced poor light from the production areas, offices and exterior lighting, and replacing them with new energy-efficient LED lamps and ballasts. The longer-lasting LEDs were cooler and required less maintenance, as a result, Rolls-Royce not only saved on energy costs, but they were also able to find modest savings in both maintenance costs and lower air conditioning expenses.
This project will help Rolls-Royce continue to deliver on their drive for sustainability. energy savings and coupled with utility incentives from The Port of Oakland, will achieve a financial payback in 1.6 years.
• Annual Energy Demand Reduction:805 kW
• Annual Energy Consumption Saving: >687,000 kWh
Coupled with utility incentives from The Port of Oakland, Rolls-Royce will receive financial payback in 1.6 years.
- > $137,000 in savings in reduced energy use and maintenance cost avoidance are forecast for the first year.
The longer-lasting LEDs were cooler and required less maintenance, as a result, Rolls-Royce not only saved on energy costs, but they were also able to find modest savings in both maintenance costs and lower air conditioning expenses.
Adidas is working hard to find new and better ways to reduce their carbon footprint. As a result, they have made major investments to improving the energy efficiency of their facilities and buildings. Understandably, after finding success with lighting projects in many of their facilities, they wanted even more.
Most people know Adidas as a sporting goods and apparel company, but what they don’t know is that in the background, Adidas is driving their business toward sustainability and energy efficiency. Adidas has taken on several projects to improve the energy efficiency of their lighting systems throughout many of their facilities. After seeing tremendous success with these projects, Adidas was interested in doing even more. They wanted to implement new lighting technologies that would help them continue to reduce their carbon footprint while also improving the lighting within their facilities. They decided to kick this project off in their Brantford, Ontario facility, with the aim to improve the energy efficiency, working conditions, and safety and security of the facility, and they came to Eco Engineering to get the job done.
Eco Engineering designed and implemented the primary solution for this lighting project, LED high bay fixtures. These fixtures are not only energy efficient, but they are designed to better distribute light at a lower operating cost while also utilizing advanced lighting control with wireless intelligent sensors. These unique sensors used data to help create optimized light profiles for various locations throughout the facility. They captured lighting, energy, and facility data and sent it to a central control module. This model was then used to interpret the data and create specific light profiles for each fixture in each work area. Additionally, the system was connected to the network, allowing for local and remote access to alter the lighting and energy profiles. Once the installation was complete, Eco Engineering trained the staff on the lighting control system and profiles.
After implementing and refining the profiles established in the lighting control system, actual energy savings surpassed initial estimates as light output was reduced by as much as 40% while still meeting facility light level standards.
- First year forecast: more than 570 kW demand reduction
- Annual Consumption Savings: over 2.1 million kWh annually
- Estimated to conserve 57% energy with fixtures operating at full light output
The project easily achieved the ROI metrics Adidas established. They coupled these savings with credits from the local utility provider, Hydro One, adding even more value to their project.
- Exceeded annual savings projection of $373,00
- Forecasted to deliver a minimum of $2.5 million in total energy savings over the next 10 years
They captured lighting, energy, and facility data and sent it to a central control module. This model was then used to interpret the data and create specific light profiles for each fixture in each work area.
Duke Energy makes life better for millions of people every day by providing electric and gas services in a sustainable way; it’s affordable, reliable, and clean. Duke is the largest electric power holding company in the United States, supplying and delivering energy to approximately 7.2 million U.S. customers. The Gibson Plant is the largest coal-fired plant in the US and has a 3.145 megawatt capacity.
Despite being the largest coal-fired plant in Duke Energy’s holdings, the Gibson Plant’s lighting system was outdated and dangerous. The lighting in the plant was high-pressure sodium HID technology which output yellow light, was slow to start or re-strike when hot and required new bulbs every 15,000-30,000 hours. Expensive, hot, dangerous, and…well…old. With a strong focus on employee safety, Duke knew they needed to improve this lighting system. They were looking for a system that could provide an improved working environment, lower maintenance costs, and energy savings.
Eco Engineering started by auditing the 300,000-square-foot area of the facility. The audit revealed a difficult situation; the area was a high-temperature environment (ambient up to 55c for some areas), with damp & wet locations, and high amounts of coal dust in the air. These are all ingredients for a perfect storm, and we knew that our design had to precisely account for each of these factors. As a result, we started by selecting LED fixtures with ratings for wet locations and that had various Classes of “Hazardous Location” ratings. The LED fixtures have multiple “drivers” (power sources), ensuring that the lights will still produce light even in the rarest failure. These fixtures also produce white light, which offers much better visibility and improves safety conditions. Finally, the new fixtures are “instant-on,” and they don’t require the 20-40 minute “hot re-strike” delay.
Additionally, many of the locations within the facility are difficult to access, as a result, the new LED light fixtures used in this project have fixtures have an unprecedented 10-year warranty, thus eliminating the ongoing maintenance/servicing costs of the existing lighting system. Beyond that, the optimized, engineering design of the system allowed Duke Energy to use fewer fixtures in some areas.
Duke Energy’s lighting project came with a myriad of benefits, from improved energy savings to reduced carbon emissions.
- Forecasted annual consumption savings: 623,816 kW per year
- Prevented the emission of 957,574 lbs of carbon dioxide per year
While the measured saving incentives for this project are clear, the improved safety for Duke’s employees, the quality and safety of the system, and the unprecedented 10-year warranty for this project are incentives that are much harder to quantify.
- Forecasted Energy Expenses: $63,385 savings per year
The audit revealed a difficult situation; the area was a high-temperature environment (ambient up to 55c for some areas), with damp & wet locations, and high amounts of coal dust in the air.
EMD Millipore, a division of Merck, produces fine chemicals and additives for a variety of applications in the life sciences industry. As a global leader in Environmental and Social Responsibility, EMD Millipore is in the midst of a multi-year effort to reduce greenhouse gas emissions, and divert a substantial tonnage of waste from landfills or incineration. They continue to develop and grow the industry’s leading Green Chemistry platform.
In its 20-building campus in Cincinnati, EMD Millipore has been updating its light fixtures on an as-needed basis. While this method has been mostly sufficient, it has also created occasional lighting failures resulting from old fixtures or blending different products. As a result, EMD was keenly aware that the entire campus, including exterior lighting areas, was in need of a new comprehensive lighting plan. They wanted to use new technology to maximize energy savings while providing a standardized framework to reduce operating expenses.
Eco Engineering based the entire design and accompanying financial projections on a detailed engineering-grade audit we performed of the EMD Millipore complex. The audit revealed that the spaces throughout the facility had diverse needs. As a result, we opted to use a variety of LED technologies to meet the specialized requirements for each of these unique spaces. Additionally, we used occupancy and motion controls to create a customized framework that would reduce the operating hours of fixtures on a space-by-space basis. We also installed special explosion-proof Class 1 LED fixtures in sensitive production areas.
In the exterior areas surrounding the buildings and parking garages, we upgraded their lighting system to long-lasting, energy-efficient LED products, helping to improve safety and lower maintenance costs.
The design and installation for this project were conducted in two phases to ensure there were no disruptions to production areas. Additionally, all old lighting was disposed of using the strict EPA standards to ensure the project was as eco-friendly and sustainable as possible.
EMD Millipore’s project met the rigorous standards they set forth for lighting quality, safety standards, sustainability objectives, and financial expectations.
- Annual Demand Reductions: 1,031 kW
- Annual Consumption Savings: Over 414,150 kWh
The project is estimated to deliver total energy savings of $38,652 for the first year following the renovation. Over $235,000 in savings is forecast over the next five years.
- Estimated energy savings in first year: $38,652
- Estimated energy savings in five years: >$235,000
- Duke Energy rebates: $32,000