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Intelligent Lighting System in Contract Manufacturing Facility

Expected to save 1,036,669 kWh annually

Established in 1953 and located in New Britain, Connecticut, Creed Monarch specializes
in the contract manufacturing of precision machined ferrous and non-ferrous alloy
components. To serve a diversified account base with customers in industries ranging
from automotive and aerospace to munitions and hardware, Creed Monarch operates
a 140,000-square foot manufacturing facility that employs more than 260 people, with
sales in excess of $42 million in 2010.
As a premier provider of precision machined components, including both single piece
and high-volume, automated parts production, Creed Monarchs management team
is committed to staying at the forefront of its industry a philosophy that extends
to all aspects of its business. So when it came to replacing the lighting within its
manufacturing facility, the management team decided they would wait until they found
the ideal lighting solution one that met a rigorous set of energy efficiency, light
quality and sustainability criteria defined as must-haves.
Working with Energy Services Group, a Marion, Connecticut based firm specializing
in high-efficiency replacement lighting for industrial businesses, the management team
at Creed Monarch spent more than 10 years searching for a lighting solution that met
all of their criteria. They finally found that solution with the Intelligent LED Lighting
System from Digital Lumens.
Over the years, weve looked at many alternatives for our facility, none of which met
all of the criteria we deemed critical to moving forward with a new lighting investment,
said Paul Stawarz, Facility Manager for Creed Monarch. Time and again, two essential
ingredients were missing: integrated sensors and centralized control. As machinery is
brought on- and off-line to fill customer orders, we knew we would leave significant
savings on the table if we could not manage lighting behaviors individually, by zone or
facility-wide. Digital Lumens does just that as part of a comprehensive system that can
be continuously tuned to meet our shop floor requirements.
More than just a one-for-one replacement for their 400-watt high-pressure sodium
(HPS) lighting, the Intelligent Lighting System delivered on the teams vision of a future
where lighting is an easily managed asset that can be controlled all the way down to
the individual fixture level. In fact, the Digital Lumens system is now providing Creed
Monarch with:
Massive energy savings. Currently in the 75% range and projected to reach up
to 90% within the first year as the management team continues to fine tune lighting
delivery. With projected energy savings of 1,036,669 kWh annually, or $108,436 at
$0.1046 per kWh, the company is on-track to secure a rapid payback, while maximizing
Connecticut Light & Power utility rebates and energy efficiency incentives.
Facility-wide, zone- and fixture-level control over lighting. With occupancy
sensors and wireless networking integrated into every fixture, the management team
has complete, centralized control over how lighting is used within its facility and the
flexibility needed to match specific lighting needs to the constantly changing nature
of the work associated with contract manufacturing.
Higher, better quality lighting and illumination levels. Before and after
pictures clearly illustrate dramatically improved light levels and the benefits of the
Creed Monarch Ends Ten-Year Search for High Efficiency
Lighting with Integrated Sensors
Figure 1: LightRules reports show energy use
and occupancy so that the Creed Monarch
management team can optimize lighting settings
to meet machinists' requirements.
New Britain, CT
140,000 ft
Up to 12 x 6
Manufacturing Facility
Up to 100F at roof
Case Study
Creed Monarch Inc. Case Study
Digital Lumens high color rendering index (CRI) LEDs at Creed
Monarch. Within this large, highly concentrated manufacturing
space, colors are sharper; aisles and machinery are well lighted,
and light levels are higher around the operating surfaces central
to the machinists' work.
Instantaneous on, off or dimming without impacting
fixture longevity or lamp life. With HPS or fluorescent
lighting, every time a fixture is turned on or off, it reduces both
fixture longevity and lamp life. Furthermore, off isnt really off,
as these fixtures continue to consume electricity even in an
off state. With the Digital Lumens system, off really means off;
dim means whatever level of dimming management defines; and,
when an occupancy sensor is triggered, lighting instantaneously
returns to full on, enabling management to comfortably and
safely eliminate unused lighting to save energy.
Maintenance-free lighting well-suited to a rugged
industrial environment. With independent lab-rated lifetimes
in excess of 50,000-hours without re-lamping or re-ballasting,
the Digital Lumens LED-based lighting eliminates maintenance
costs associated with HPS lighting (or any fluorescent alternative).
Creed Monarch operates on a ten- to twelve-hour schedule five
days a week, with Saturdays often required to catch up to high
order volumes. Daily work activity centers on the machines, or
cells, required to complete specific customer orders. This means
that at any given time, individual workstations, groups of machines,
aisles or storage spaces are frequently unoccupied, providing
opportunities to dim or turn off individual or groups of lights to
maximize energy savings.
Using the Intelligent Lighting Systems integrated LightRules lighting
management software, Creed Monarch is now able to fine tune
its lighting to match these work patterns while safely eliminating
unused light. This level of flexibility enables them to:
Group fixtures around specific clusters of machines used to
complete specific tasks, and control their settings and behaviors.
As management learns more about how lighting is used
(now that they no longer are locked into 100% on fixtures) they
are slowly altering timeout and dimming settings to maximize
light use and savings.
Re-group lighting to account for unexpected (at time of
installation) needs or changing business conditions (new
machines or changed floor plans).
Isolate, at will, any single fixture (e.g., over a specific machine or
main entryway) and have it behave differently from the lighting
around it.
Dim lighting in aisles surrounding machinery by 40% and in
less traveled aisles by 20%, knowing that they can increase or
decrease these settings at any time through LightRules, without
ever having to touch a light fixture.
Have lighting behave differently depending on the time of day
(e.g., night cleaning versus production shifts); week or weekend;
or to account for holiday schedules.
Learn more about how lighting is being used, such as where
activity is concentrated in the facility or when peak usage
occurs, through integrated reports that document lighting use
and energy savings.
And finally, know that if the lights are dimmed or programmed
to shut off as per the schedule entered, the occupancy sensor
will instantly turn on the light if presence is detected, assuring
worker safety.
While the Creed Monarch team considered fluorescent alternatives
with add-on sensors, they lacked the level of flexibility management
required. Additionally, the management team was adamantly against
any solution that would force them to lock-in fixture settings at
installation (or hire lighting engineers to physically change fixture/
sensor settings post-installation) or restricted timeout settings
to a limited number of pre-defined intervals.
Alternatively, they liked the fact that the Intelligent Lighting
Systems sensors were not a bolted-on afterthought, but rather
an integral part of system designed for durability, flexibility, light
quality and energy savings. According to Mr. Stawarz, You cannot
save more than off, but you need the tools necessary to intelligently
and safely turn lighting off when it is not needed. That is
what the Digital Lumens system provides Creed Monarch.
The decision to upgrade our lighting was really a ten-year process.
We saw countless proposals and new technologies through the
years, but Digital Lumens was the first to address our need for
control of individual fixtures, said Richard Creed, President of
Creed Monarch. Digital Lumens provided the only lights with
controls and sensing that were two generations ahead of anything
we saw. We are able to dim, shut off and customize light levels
without affecting the life or performance of the light. We want
to see Digital Lumens succeed with us, and we are looking at this
as a long-term relationship.
All Rights Reserved 2012
Digital Lumens Incorporated
Subject to change without notice.
DOC-000115-00 Rev A 09-12
374 Congress Street, Suite 600
Boston, MA 02210
+1 (617) 723-1200
Figure 2: The Creed Monarch facility before (left) and after (right)
installation of the Intelligent LED Lighting System from Digital Lumens.
Installation of Digital Lumens LED-based Intelligent Lighting
System throughout 460,000-square-foot facility slashes
companys carbon footprint and increases light levels by 53%
With annual revenues approaching $3 billion, Maines Paper and Food Service, Inc.
is one of the nations largest broadline food distributors. Through its network
of warehouse facilities, the company serves customers in 35 states, offering
competitively priced, quality food service products backed by exceptional
levels of service. Operationally, Maines leads the industry in its commitment to
sustainability and setting new standards in workplace productivity and safety.
It is this commitment to excellence that led Maines to re-evaluate the lighting
needs at its 460,000-square foot headquarters facility in Conklin, NY. Like any
large warehouse with 24x7 operations, the spotlessly clean Conklin facility
bustles with activity across all shifts. To rapidly pick and replenish product,
forklift operators regularly zip back and forth through both ambient space and
cold storage environments, which range from 70F dry storage areas to 40F
refrigerated spaces to -20F ice cream freezers. They rely on proper lighting
to ensure safety and performance.
Until recently, the facility was illuminated with hundreds of 400W high-intensity
discharge (HID) fixtures a decade-old solution that resulted in under-lit
spaces and poor-quality light. The challenge for the management team was
finding a more energy efficient and sustainable solution that produced and
subsequently maintained higher levels of quality light, a key driver of safety
and productivity.
Case Study
Maines Paper and Food Service, Inc. Reduces Lighting-Related
Energy Use by 87% in Showcase Facility
Maines Paper and
Food Service, Inc.
Conklin, NY
460,000 ft
24 x 7
Ambient, cold, and refrigerated spaces
-20 to 70F
400W High Pressure Sodium (HPS)
Digital Lumens Intelligent Lighting System
Figure 1: Before and After
The images above show the original 400W high-pressure sodium fxtures (left), which give
of a signature yellowish light. On the right, the Digital Lumens Intelligent Lighting System
provides high-intensity illumination when and where needed, using only 160W when
fully illuminated.
Our experience with Digital Lumens put
to rest any questions we had regarding the
use of LED-based light fxtures in complex
warehouse environments.
With the Intelligent Lighting System, we
now have access to a long-lifecycle, low
maintenance, high-quality lighting source that
provides the in-depth usage data we require
to fne-tune our system to meet actual, versus
estimated, needs.
The result is a smarter, vastly more efcient
and sustainable solution that puts us frmly in
control of our lighting, today and in the future.
Pat DeOrdio, VP of Operations,
Maines Paper and Food Service, Inc.
Maines Paper and Food Service, Inc.
The facilities team considered fluorescent fixtures as a possible solution in
both cold and dry spaces. However, to achieve desired light levels, they would
need to install 8-lamp high-intensity fluorescents (HIF) at 300W each, which
quickly eroded the potential energy savings and, as a mercury-based light
source, created hazardous waste issues and costs. There were also significant
concerns surrounding fluorescent fixture performance in a cold environment.
The search continued.
The management team, working with their energy efficiency partner, then
evaluated a new class of highly efficient LED-based lighting solution from Digital
Lumens, the Intelligent Lighting System. Designed specifically for demanding
industrial applications, the Intelligent Lighting System integrates high-intensity
LEDs, sensing, networking and software-based intelligence into a single system
that maximizes light delivery and minimizes energy use.
Following a pilot installation, which included carefully evaluating the system
in both dry and cold environments, the Maines team decided to retrofit its
400W HID fixtures with the Digital Lumens solution. Installed as one-for-one
replacements for existing high bay fixtures, the Intelligent Lighting System:
Performed exceptionally well in all of the facilitys environments;
Required little or no maintenance or re-lamping;
Produced instant, high-quality light when, and where needed; and,
Provided the Maines team with the data they required to document energy
use and continuously improve performance over time.
Maines installation of the Digital Lumens Intelligence Lighting System qualified for
financial incentives from the New York State Energy Research and Development
Authority (NYSERDA), an organization that helps businesses across the
state enhance operational efficiency by funding sustainable, energy-efficient
projects. NYSERDAs focus on reducing energy consumption and protecting
the environment dovetailed nicely with Maines strategic goals.
With a payback of less than two years, driven by massive energy savings,
the Digital Lumens solution has proven to be a perfect fit for Maines. Since
deployment, the Intelligent Lighting System has dramatically increased light
levels for facility staff, while driving down energy usage by a documented 87%.
Maines expects to save 1,726,108 kWh and eliminate 1,240 metric tons of
carbon dioxide (CO
) per year equivalent to removing 200 homes per year
from the grid. Those results contribute significantly to the safe and sustainable
work environment at Maines.
Case Study
29 Portland St, Suite 400
Boston, MA 024-204
(67) 723-200
DOC-000034-00 Rev B 04-
All Rights Reserved 20
Digital Lumens Incorporated
US and international
patents pending
Figure 4: Digital Lumens Intelligent Lighting System uses 89.3%
fewer kWh than alternatives. Data gathered at 15-minute
intervals from a 400W HID fxture, a 300W fuorescent
alternative, and the Digital Lumens system shows cumulative
energy use in a 24-hour period. The Digital Lumens fxture
enters a true standby mode and consumes zero power
whenever an aisle or work area is vacant and uses only
1.2 kWh/day. The HID fxture must remain ON to ensure
immediate light delivery (11.96 kWh/day). The fuorescent
consumes 6.98 kWh/day in standby mode.
Figure 2: The Maines team that evaluated and selected the
Digital Lumens solution. From the left, James McColloch,
Director of the Warehouse; Eddy Osorio, Facility Manager; and
Pat DeOrdio, Vice President of Operations.



















































Time of Day
Average Power Consumption
400W HPS
11.16 kWh / day
8-lamp T8 (dual ballast)
6.98 kWh / day
Digital Lumens ILE-HB-3
1.20 kWh / day
15 minute intervals
Figure 3: Light Meter Reading. The Intelligent Lighting System
achieves 20.04 footcandles of illumination at the aisle task level.
Vermont Retailer Enhances Product Presentation and
Shelf Life of Perishables While Saving Nearly
100,000 kWh of Energy Per Year
City Market, Onion River Co-op, is a 16,000 sq. ft. community-owned
food cooperative located in Burlington, Vermont. Open 363 days of the
year, it is the citys only downtown grocery store, offering a wide range of
conventional, organic, and local products to the more than 3,000 customers
who pass through its doors each day.
Committed to continuously improving the sustainability of its grocery
operations, the City Market management team actively works to find
customer-friendly solutions that are both smart choices for the environment
and economically sound. So when the team was confronted with the need
to replace the stores aging lighting, which was becoming extremely cost
prohibitive to operate and maintain, they turned their attention toward a
new generation of ultra-efficient, LED-based solutions.
To aid them in through the evaluation and installation process, the City Market
team turned to the Leading Edge Design Group, a nationally recognized
provider of LED lighting and wireless lighting control technologies. Following
a careful examination of all their options, the team decided to deploy the
Intelligent Lighting System from Digital Lumens in the retail areas of its store.
There is no question that the opportunity to dramatically lower our energy
costs and make substantial contributions to our sustainability agenda was an
important motivator in our decision to deploy the Digital Lumens system,
said Brent Demers, Facilities Manager for City Market. But at the end
of the day, it was lighting quality that clinched the deal. In a retail grocery
environment, delivering a positive customer experience is critical to success,
and lighting quality how you present your products to customers plays
a major role in creating that experience.
Finding the right solution for customers and employees was a top priority
for the facilities team. They needed to find an attractive solution with a
high color rendering index and proper color temperature to accentuate
produce, meat, prepared foods, and deli offerings, while saving enough
energy to ensure the lighting improvements were cost effective both
in the short term and over the long haul. With Digital Lumens, they found
this solution and more.
In addition to improved lighting quality, color and aesthetics, the Digital
Lumens Intelligent Lighting system provides City Market with:
Energy saving of approximately 100,000 kWh per year equal to the
removal of more than 64 tons of carbon dioxide from the atmosphere;
An extremely low-maintenance, mercury-free lighting system with a
50,000+ hour lifecycle per fixture (versus 8,500 for the existing metal
halide fixtures);
Light Quality Plays Central Role in Energy Efficiency Retrofit
at City Market
Figure 1: A standard LightRules report shows City Market's
staff the lighting energy use and the daily average.
City Market
Onion River Co-op
363 days per year, 7 a.m. to 11 p.m.
Retail grocery, ambient, and refrigerated spaces
65 to 75F
400 W metal halide
3 shifts x 7 days
3.5 (versus 46 for a traditional solution)
Leading Edge Design Group
Burlington Electric Department (BED)
Case Study
Burlington, VT 16,000 ft
City Market, Onion River Co-op
Longer shelf life for produce and meat through the elimination of
damaging ultra-violet light rays and excessive lamp heat, which causes
premature aging and significantly impacts profitability;
A reduced burden on the air conditioning systems, because the Digital
Lumens fixtures generate dramatically less heat than legacy lighting
systems; and,
A payback of less than 1 years.
To help replace City Markets existing metal halide lighting with the dramatically
more efficient Intelligent Lighting system, the stores utility company, Burlington
Electric Department, provided an energy efficiency incentive based on the
energy savings.
The transition from a metal halide to LED-based lighting system, however,
only tells part of the story behind the extraordinary savings City Market has,
and is continuing to, accrue. The rest of the story is the Intelligent Lighting
Systems integrated intelligence, and LightRules, the software-based lighting
management system. LightRules is enabling the City Market team to fine-tune
its lighting system based on real usage and performance data, to secure further
efficiency gains. Specifically, LightRules provides the management team with:
Accurate data on energy usage, lighting trends and occupancy
patterns, such as kWhs (by fixture, specified area, or store-wide),
usage over time (minute, hour, day, week, etc.), and a wide-range of
performance metrics;
The ability to configure lighting behaviors, such as delay settings for
dimming or turning lights off when a space is vacated, via easy-to-use,
rules-based software controls; and
Detailed reports that document the savings for internal purposes and to
substantiate rebate incentive claims with Burlington Electric Department,
City Markets utility company.
Not only does the Digital Lumens system use significantly less power
to produce remarkably high-quality lighting, but through LightRules we
gain the information and tools we need to rack up significant additional
savings, continued Demers. Given the high cost associated with operating
and maintaining the old lighting system, our only regret is that we didnt
do this sooner.
Installed throughout the store, the new lighting is producing dividends in myriad
ways. Customers appreciate the new lighting and the fact that City Market
is using significantly less energy to deliver a better quality light, which more
closely aligns with many of its customers environmental goals and vision of
a sustainable business.
For City Market, the new lighting system delivers on three key fronts: its
vision of better quality lighting that enhances the shopping experience; its goal
to dramatically reduce energy usage with an economically sound investment
that makes good business sense; and, to reap significant bottom line savings
for its cooperative members.
According to Mr. Demers, Now THAT is the definition of project success!"
Case Study
Figure 2: Digital Lumens LED f ixtures improve lighting
quality throughout the City Market retail environment.
All Rights Reserved 2011
Digital Lumens Incorporated
Subject to change without notice.
DOC-000053-00 Rev A 08-11
110 Canal St, 7th Floor
Boston, MA USA 02114
+1 (617) 723-1200
New Intelligent LED Lighting System Reduces
Lighting-Related Energy Use by 90%,
Saving More Than 482,000 kWh Annually
Headquartered in Pembroke, NH, Associated Grocers of New England
was founded in 1946 by a small group of independent grocers interested
in consolidating their buying power to better serve customers. Today,
Associated Grocers of New England (AG New England) is one of the
nations largest retailer-owned purchasing and distribution cooperatives,
serving more than 600 independent food stores throughout New England
and Upstate New York.
In addition to providing retail support services, AG New England operates
a 380,000-square foot warehousing and distribution center, which employs
more than 300 service professionals in areas ranging from advertising and
marketing to merchandising and warehousing operations. This best practice
facility incorporates state-of-the-art shipping, receiving, storing, and handling
technologies to enable AG New England to maintain an exceptionally high level
of service and on-time delivery record for the benefit of its member stores.
Like every other cold storage warehousing facility in the country, however,
AG New England has wrestled with the high energy and maintenance costs
associated with lighting refrigerated spaces. Cold temperatures put an
incredible strain on its traditional fluorescent fixtures, leading to decreased
lighting output, high lamp burnout rates and ongoing maintenance issues.
To meet its energy efficiency and cost containment goals, the management
team at AG New England was determined to find a safe, no-compromise
lighting solution for its cold storage warehousing area.
Working with the Leading Edge Design Group (LEDG), an energy optimization
services firm offering lighting design and consultation services, AG New
England evaluated its options. The challenge was to find a one-for-one
replacement alternative for its T5 HO lighting fixtures located within a
56,600-square foot cold storage area. Maintained at a consistent -15 F
operating temperature, the fixtures simply consumed too much energy,
required too much maintenance and fell well-short of the cooperative's
sustainability goals.
Following a thorough review, LEDG recommended replacing the facility's
fluorescent fixtures with the LED-based Intelligent Lighting System from
Digital Lumens. By incorporating smart, LED fixturesall with built-in
occupancy sensors, wireless networking and software controlsthe
Intelligent Lighting System offered AG New England a clear path to unmatched
energy efficiency savings, flexibility and control over how lighting was used
within its cold storage area.
Associated Grocers of New England Replaces
Fluorescents for Major Savings
Figure 1: A standard LightRules report shows AGNE's staff
the lighting energy use and the daily average.
Associated Grocers of
New England (AGNE)
Pembroke, NH
380,000 ft
with 56,000 ft
cold storage
lighting upgrade from Digital Lumens
24 x 6
-15 F
T5 HO fuorescent
Leading Edge Design Group (LEDG)
Public Service of New Hampshire
Case Study
Associated Grocers of New England
In addition to performing exceptionally well in cold temperature
environments, the Intelligent Lighting Systems highly integrated
approach to lighting enabled AG New England to:
Dramatically improve light levels (from 9 to 25 foot
candles) while reducing energy usage by up to 90%.
Easily save more than 482,000 kWh/year, reducing
operating costs by more than $52,000 annually.
Significantly reduce demand on refrigeration systems,
further increasing energy savings.
Eliminate ongoing maintenance (for example, re-lamping
and re-ballasting) costs.
Enhance workplace safety through improved light levels
and quality.
For years, lighting our cold storage areas has been fraught
with challenges, ranging from durability and efficiency issues,
to heat dissipation and its impact on refrigeration loads, said
Bruce Courtois, Facilities Manager for Associated Grocers of
New England. Then we installed the Digital Lumens system and literally overnight, all of these problems just simply went away.
Immediately, we recognized dramatic energy savings. Light levels improved, re-lamping exercises ended and we eliminated ongoing
maintenance expenses. To say that we were pleased with the outcome would be an understatementwe are thrilled and delighted.
In addition to working with AG New England to develop a comprehensive lighting and energy assessment for its cold storage area
including target light levels, system performance and evaluation metricsthe LEDG team also managed the process of securing
a utility company incentive. The cooperatives utility company, Public Service of New Hampshire, contributed to the installation
costs associated with replacing aging lighting systems through its NHSaves@Work/Large Business Energy Solutions Program.
Since its founding in 1946, AG New England has undergone many lighting upgrades, all of which delivered incremental improvements
in efficiency, lamp source longevity and maintenance. Yet the underlying problems associated with lighting refrigerated environments
with fluorescent fixtures remainedpoor light output, poor performance and high maintenance costs.
With LED-based lighting, which doesnt degrade in cold environments, all this has changed. Well-designed LEDs can be used as
neededturned off and instantaneously back on without warm-up times or impacting longevityand save energy along the way.
Furthermore, they are inherently controllable when combined with integrated sensors, wireless networks, and control software.
The Digital Lumens Intelligent Lighting System combines all of these ingredients to enable AG New England to dramatically reduce
its energy usage while improving light levels. It also offers:
A single, integrated approach to lighting, supported by a single vendor and proven in real-world industrial settings, eliminating
the need to cobble together and support a multi-vendor solution.
Integrated lighting management software, LightRules, that enables facility managers to quickly review and fine-tune lighting
behaviors (such as how long a fixture stays on after a space is vacated), with only a few keystrokes and without touching a
lighting fixture.
Access to detailed light usage and occupancy reports that document how lighting is used within the facility, providing the
information facility managers need to safely manage fixture settings and substantiate the energy savings.
The ability to lock-in dramatic energy savings over the long-haul in the face of rising energy costs.
Historically, lighting our freezer space has always presented a significant challenge, due to the harsh environment and its impact
on light quality, continued Mr. Courtois. Not only has the Digital Lumens system solved these problems, but the lighting
system is now delivering information and data to us, giving us value from our lighting investment that we never anticipated.
Today, we have complete operational control over our lighting, resulting in better lighting delivery, lower energy costs and
significant bottom-line savings.
Case Study
Figure 2: Digital Lumens LED f ixtures improve lighting
quality throughout the AGNE warehouse environment.
All Rights Reserved 2012
Digital Lumens Incorporated
Subject to change without notice.
DOC-000092-00 Rev A 06-12
110 Canal St, 7th Floor
Boston, MA USA 02114
+1 (617) 723-1200
Chicago-Area Warehouse Management Company
Reduces Per Square Foot Lighting Costs to 3.9,
Saving More Than 1,237,626 kWh Annually
Founded in 1914, Silver Beauty is a growing warehousing management company that
builds and leases warehouses in the Chicago area. With more than 391,560 ft
of space
under management, the company has more than doubled its inventory over the last ten
years, including the addition of two warehousing facilities in the Clearing Industrial Park.
Constructed in 2002 and 2009, respectively, the facilities are located on the outskirts of
Chicago with easy access to transportation routes. They house Midwest warehousing
operations for Graham Packaging, a worldwide leader in the design, manufacture and
sale of rigid plastic containers.
Built with the philosophy that highly efficient, well-designed facilities result in satisfied,
long-term tenantsthe bread and butter of Silver Beautys businessthe companys
management team has a relentless focus on evaluating all available options before
committing to capital improvements for any of its warehousing facilities. So when the
need arose to replace the lighting in Warehouse
5, a 177,413 ft
unheated facility that
operates on a 24x7 basis year-round, the search for a new solution was wide-ranging
and exhaustive.
At the center of Silver Beautys decision to replace Warehouse
5s 1000W metal halide
fixtures were four fundamental challenges: the fixtures consumed too much energy, didnt
perform particularly well in unheated environments in a cold winter climate, couldnt be
easily dimmed or turned off and, to the chagrin of the tenants, had developed a hum
that was increasing in intensity and deemed irresolvable by the fixtures manufacturer.
While state-of-the-art at the time of installation, significant changes in lighting
technologyparticularly in the areas of energy efficiency and light outputsuggested
that Warehouse
5s challenges were solvable. Working with their energy efficiency
consultant, Green Light Midwest, Silver Beauty began a comprehensive review of
its options, involving more than 30 LED fixture manufacturers, an equal number of
fluorescent alternatives, and a thorough review of new fluorescent induction technologies.
Leaving no stone left unturned, the Silver Beauty management team selected the Intelligent
LED Lighting System from Digital Lumens.
With documented savings of 90%, the Intelligent Lighting System has reduced the
facilitys $50,000 annual operating budget for lighting in Warehouse
5 to just
under $5,000. According to the managing director of Silver Beauty, Gary Raymond,
the energy savings are driven by a level of control over lighting that is unmatched
within the LED lighting arena.
The overwhelming success of our lighting installation goes well beyond the savings
we immediately accrued by simply switching out our metal halide fixtures for the
much more efficient LEDs from Digital Lumens, said Gary Raymond, Managing
Partner for Silver Beauty. Due to the range of smart capabilities included with its
systemsmotion and daylight harvesting sensors in each fixture, for examplewe are
saving an additional 75% of the remaining energy use. All told, that means we are using
well under 10% of the roughly $50,000 annual costs we had with all metal halide lighting.
And the best part is that our LED lighting looks fantastic and performs flawlessly within
the entire range of temperatures in which our facility operates.
Silver Beauty Reduces Lighting-Related Energy Use by 95%
Figure 1: Using the integrated LightRules reporting
capabilities, the management team has detailed
information on lighting use, such as kWh used and
occupancy patterns.
Silver Beauty
Chicago, IL
177,413 ft
24 x 7
Ambient Warehouse
1000W Metal Halide
Green Light
Case Study
Silver Beauty Case Study
With the Intelligent Lighting System, Silver Beauty gained brighter,
higher quality light that is better suited to the operating realities
within its facility, at a fraction of the annual operating costs of
its metal halide fixtures. Other important criteria that impacted
Silver Beautys decision to select the Digital Lumens system
included its ability to deliver:
Higher quality light that comfortably exceeds the
70% efficiency improvement required for rebates
from ComEd, Silver Beautys utility company. With an
equivalent foot-candle readingthree feet off the floorthe
previous metal halide lamps consumed approximately 138,000
watts of electricity each hour versus 50,000 for the Digital
Lumens 18,000-lumen fixtures.
Significant additional savings by enabling facility
management to easily control lighting behaviors, such
as when a fixture (or groups of fixtures) turn off or
what the dimming levels are. When a space is unoccupied
in Warehouse
5, for example, lighting is dimmed to 40% in
well-traveled aisles and 10% elsewhere for security purposes.
Lighting instantly turns back on when personnel, such as a
rapidly moving forklift operator, trigger an occupancy sensor.
Daylight harvesting capabilities that fully leverage all
of the natural light from Warehouse
5s extensive
skylight system. On sunny days, skylights provide up to 40%
of the lighting needed to illuminate the warehouse. Because
the Digital Lumens fixtures have integrated daylight sensors,
they assess available ambient light and dim or turn off when
enough natural light is present to meet the facilitys 20 foot-
candle target.
Rapid on/off cycling. Unlike metal halide lamp sources, LEDs
perform exceptionally well in cold temperature environments
(e.g. Chicago winters) and can be cycled on/off millions of
times, without compromising fixture lifetime or lumen output,
throughout its 50,000hour lifespan. For Warehouse
5, this
equates to years of additional service without the need to
re-lamp or otherwise touch a lighting fixture.
Quiet operation. The Digital Lumens system operates silently,
eliminating the humming sound from the previous fixtures.
About four years ago, we installed T5 fluorescents in another
warehouse and there is no question that their performance
diminishes in cold, unheated spaces, and with frequent on-off
cycles, said Mr. Raymond. In fact, while we expected our T5
lamps to last over 33,000 hours, we are consistently re-lamping
significantly sooner, in the 10,000- to 15,000-hour range. Part of
that is due to cold temperature operation, but also because each
time the T5 motion sensors turn the lights on or off, we shorten
the life of those lamps. At 26-feet high and 6 lamps per fixture,
changing T5 lamps is a hassle that requires our tenant to rent a
cherry picker. You can easily imagine why they are thrilled with
the Digital Lumens system in this facility.
As forklift operators rapidly move through the facility to accomplish
their tasks, how quickly lights are turned on and off, or dimmed,
has direct implications on safety and energy savings.
In another facility, for example, fluorescent lights are dimmed by
turning off four of the six lamps in the fixture. This means that
granular dimming settings, such as 40% for aisles and 10% for
security lighting in less traveled areas, is not possible. Furthermore,
the fluorescent lighting takes a few seconds to ramp back up to
full illumination, unlike LEDs which instantaneously return to full
on, so forklift operators are often well into a space before light
levels return to 100% lighting.
Alternatively, with the Digital Lumens LED system, highly granular
dimming settingsfixture-by-fixtureare easily set and adjusted,
providing much greater control and energy savings. Silver Beauty
is using the Intelligent Lighting System to:
Fine-tune fixture or system-wide settings (via LightRules
lighting management software) to try different what-if lighting
scenarios, such as how long a fixture remains on after a space is
vacated or dimming settings. This enables Silver Beautys tenant,
Graham Packaging, to continuously optimize how lighting is used
within its facility to safely achieve additional energy savings. The
ability to save lighting scenarios in LightRules enables facility
management to quickly and easily return to previously saved
settings or create new ones.
Gain insights into how lighting is used within the facility
and document the results of modifications. Using the LightRules
lighting management and reporting capabilities, the management
team has detailed, fixture-by-fixture information on lighting use,
such as kWh used, occupancy patterns and average on times by
hour, day or any other management-defined interval.
Reconfigure settings to accommodate changing operational
needs. The warehouse is a multi-tenant facility and as space
needs change, the Intelligent Lighting System provides the
flexibility Silver Beauty needs to quickly adjust without hiring
electricians, renting a cherry picker, or touching a light fixture.
Not only is our primary tenant, Graham Packaging, getting the
full benefit of our lighting investment through dramatically lower
utility bills, but they are also getting much higher quality lighting
that can be tailored to meet their specific operational needs,
continued Mr. Raymond. The Digital Lumens system is an important
component of our strategy to offer tenants superior solutions that
reduce operating costs, providing us with a significant edge in the
competitive marketplace for leased warehouse space in Chicago.
Reseller Partner: Green Light, a consulting f irm that helps tenants and
property owners reduce the operating expenses associated with energy
consumption by taking advantage of the technological advances in
eff icient lighting, environmental controls, and building envelope eff iciency
All Rights Reserved 2012
Digital Lumens Incorporated
Subject to change without notice.
DOC-000102-00 Rev A 07-12
110 Canal St, 7th Floor
Boston, MA USA 02114
+1 (617) 723-1200
Intelligent LED Lighting Uses 60% Less Lighting Energy,
Reduces Buildings Energy Intensity, and
Provides New Levels of Operational Control
Established in 1886, New Orleans Cold Storage and Warehouse Company (NOCS) is
the oldest cold storage company in North America and remains, to this day, dedicated
to providing flawless and efficient storage and logistics services to its worldwide
customer base. In addition to enabling the movement of dry, time and temperature-
sensitive cargoeither by truck, rail, container ships or breakbulk cargo vessels
the company operates 4 warehousing facilities in three strategic U.S. port cities,
including New Orleans, Houston and Charleston, with more than 12,000,000 cubic
feet of refrigerated storage capacity.
In the aftermath of Hurricane Katrina, New Orleans Cold Storage decided to build a
new 142,000-square-foot facility in the Port of New Orleans. From the very start of the
project, company management recognized that the rebuild presented an extraordinary
opportunity to re-think how energy was used, and zeroed-in on energy efficiency as the
driving force for capital investment decisions. Traditional lightingincluding the heat
it generates and corresponding impact on freezer loadswas specifically targeted for
improvement, as it consistently represented one of the highest line items in the original
facilitys budget (after refrigeration). Lighting simply consumed too much energy and
required too much maintenance, which would place an undue burden on the facilitys
budget and warehousing operations.
Working with Primus Design Services and The McDonnel Group, a construction
management company, the team at NOCS was determined to find a dramatically
more efficient, maintenance-free lighting solution to support the locations poultry
business. It found that solution and more with the Intelligent LED Lighting System
from Digital Lumens.
To say lighting has always represented a challenge for our cold storage facilities would
be an extreme understatement, said Mark Blanchard, President of New Orleans
Cold Storage. From fixture longevity and heat loads, to lamp life, maintenance and
efficiency, continuous operations in sub-zero environments stress traditional lighting,
placing a heavy burden on facility budgets and refrigeration systems. In our new facility,
weve overcome these challenges with the LED-based system from Digital Lumens,
with bottom line savings, better light quality, and unprecedented controlwithout
the disruptions associated with regularly changing burned out bulbs and ballasts.
The new cold storage warehouse, with 40-foot ceilings, has temperatures that range
from -15 F for its three Quick Freezing Rack rooms (which can freeze more than
560,000 pounds of poultry to 0 F within a 24-hour period), to -10 F for large open
storage space, and 35F for dock areas used for loading and unloading cargo. The Digital
Lumens highbay product lineavailable with either narrow optics (for racked aisles)
or wide optics (for distributing light evenly over open spaces) opticsaddressed the
varying needs of the facility while:
Saving more than 245,764 kWh in annual energy use, or 60% less than the 6-lamp
T5 high-intensity fluorescents with sensors that the builder would have specified;
New Orleans Cold Storage Taps Digital Lumens to
Light New Post-Katrina Cold Storage Warehouse
Figure 1: LightRules reports show energy use and
occupancy so that the NOCS engineering team can
optimize lighting settings and respond to changing
operational needs.
New Orleans, LA
142,000 ft
Cold Storage
-15 to 35F
6-lamp T5 HIF
Primus Builders
The McDonnel Group
Case Study
New Orleans Cold Storage Case Study
Eliminating annual maintenance costs associated with re-lamping,
re-ballasting, and the disposing of lamps containing mercury;
Reducing annual chiller costs due to the low thermal load that the
low-wattage, occupancy-driven place on the refrigeration system.
We evaluated a range of industrial LED lighting alternatives
and found that the energy efficiency and maintenance savings
from the Digital Lumens system provided a rapid payback,
while delivering exceptional performance and light quality,
said Matt Hirsch, Vice President of Sales for Primus Builders.
The NOCS installation validates our belief that well-designed
energy-efficient products are good investments, and enhance
quality and performance of critical infrastructure, while reducing
the energy intensity of the project.
In the new facility, which offers 4.3 million cubic feet of
storage, NOCS installed three state-of-the-art Quick Freeze
Rack Zones (QFRs) freezers that are maintained at -15 F.
They use a high-powered air-movement system that circulates cold
air to more cost effectively chill the chicken, helping the facility
use 1/3 the horsepower of comparable facilities.
Adding to the very real energy savings is the Intelligent Lighting
Systems unique range of features and benefits, which are enabling
the facility to:
Dim and turn off lights when a space is unoccupied.
Occupancy sensors in each fixture detect when a space is
unoccupied and automatically dim or turn off individual lights.
Unlike traditional fixtures, the LED-based Digital Lumens
fixtures instantly return to full brightness when the sensor is
activated, even in the extremely cold QFR areas.
Have detailed operational reports. LightRules, the Digital
Lumens lighting management software, wirelessly gathers data
from every fixture and provides reports showing energy use
or occupancy by room, shift or facility-wide so that the NOCS
engineering team can optimize lighting settings and respond to
changing operational needs.
Easily modify and optimize fixtures settings without
ever having to touch them. With LightRules, the NOCS
team can easily modify lighting settings via the keyboard, so
they never need to use a scissor lift to make changes.
Eliminate maintenance and mercury disposal fees.
Traditional HIF lamps require frequent re-lamping and re-
ballasting, particularly when used in cold environments or
cycled on and off to save energy, which significantly decreases
fixture life. With the Digital Lumens system, NOCS eliminated
maintenance costs altogether.
Reduce thermal load on the chiller system. The 160-Watt
fixtures, which are turned off or dimmed when areas are vacant,
use less power and generate less heat than alternatives.
Mix and match fixtures from the Digital Lumens
high bay product line to meet specific lighting needs.
With everything from refrigerated rack storage areas to
inspection and loading spaces, requiring a variety of optics
from narrow for task lighting to wide for broad and even
distributionthe Intelligent Lighting System provided NOCS
with the flexibility to match fixture choices to the specific
needs of its facility.
Unveiled at a ceremony in New Orleans attended by Louisiana
Governor, Bobby Jindal, and other local officials, supplemental
funding for the project was provided by the U.S. Army Corps of
Engineers, the Port of New Orleans, and the State of Louisiana.
According to Mark Blanchard, President of New Orleans Cold
Storage, The Digital Lumens System is delivering everything we
expected and moreenergy efficiency, light quality and cost
containment perspectivehelping ensure success for the company,
the environment, and the great State of Louisiana.
All Rights Reserved 2012
Digital Lumens Incorporated
Subject to change without notice.
DOC-000103-00 Rev A 07-12
110 Canal St, 7th Floor
Boston, MA USA 02114
+1 (617) 723-1200
Figure 2: Intelligent LED lighting in the QFRs provides light where and
when needed.
Figure 3: From the very start of the project, company management
recognized that the rebuild presented an extraordinary opportunity to
re-think how energy was used, and zeroed in on energy effciency as the
driving force for capital investment decisions.
Eliminates 427.7 Metric Tons of CO
Saves 795,656 kWh Annually
Ardo UK is a leading supplier of high-quality frozen fruit, vegetables and carbohydrates
(potato, rice and pasta), serving customers in the retail, foodservice and industrial
ingredients markets under its own brand or under customer trade labels. To support
its manufacturing and packing operations, the company operates a 80,000-cubic meter,
BRC-certified cold storage and distribution facility in Kent, with excellent links to
motorways, the port of Dover and the Channel Tunnel. The facilitys close proximity
to transportation routes enables daily service throughout the UK and Europe.
By controlling the entire production chain, from seed selection to packing and
distribution, Ardo UK fulfills its mission to preserve the gifts of nature for customers
and consumers a commitment to quality that extends to it cold storage facility. As
proud recipient of a KEiBA (Kent Excellence in Business Award) for Business Commitment
to The Environment in 2012, the facilitys robust sustainability agenda has driven a
wide range of energy efficiency and quality improvements, resulting in significant cost
savings and increased operational control. LED lighting is a case in point.
Working with the Titchfield Group, specialists in building refurbishment and construction,
the Ardo UK facility team decided to replace its aging 400-Watt HID lighting with the
Intelligent LED Lighting System from Digital Lumens. The system, which integrates
wirelessly networked intelligent LED fixtures with LightRules lighting management
software, is enabling Ardo UK to:
Reduce annual lighting energy costs by 97%.
Save more than 795,656 kWh annually and 278,000 ($450,000) over five years,
with a payback of approximately 1.8 years due to the extraordinary energy savings.
Eliminate more than 2,140 metric tons of CO2 over 5 years.
Generate meaningful UK carbon tax savings.
Write off the Project Cost in year 1 under the UK Enhanced Capital
Allowance Scheme.
Eliminate re-lamping and re-ballasting costs associated with traditional fixtures.
While the numbers are seemingly unbelievable, keep in mind that even though large
areas of our facility were unoccupied at any given moment, we were forced to leave
our old fixtures on 100% of the time due to the extended ramp up times when they
were needed, said Jon Barnes, Supply Chain Director for Ardo UK. The fact that
we are a cold storage facility with mobile racking simply compounded the challenges.
With the Digital Lumens system all these problems went away. We now have complete
control over our lighting, better light quality, and incredible savings that go directly to
the bottom line. No other option we looked at provided this level of integration and
control over fixture timeout and dimming settings, which have been so central to our
ability to optimize lighting delivery and maximize savings.
Ardo UK Reduces Annual Lighting Costs by 97% in
Cold Storage Facility with Mobile Racking
Figure 1: The 80,000 m
Ardo facility in Kent, UK
serves customers in the retail, foodservice and
industrial ingredients markets under its own brand
or under customer trade labels.
80,000 m
-27 to -22C (-17 to -7F)
Case Study
Ardo UK
ARDO UK Case Study
Ardos mobile racking storage system utilizes limited warehouse
space more effectively by expanding and contracting moveable
racks via a track system to increase usable space. As the racks
open, integrated occupancy sensors embedded in each Digital
Lumens high bay LED fixture turn lights on to provide lighting for
facility personnel. If an aisle is subsequently unoccupied for more
than 30 seconds, the lighting turns off until a sensor is reactivated
by a forklift operator, for example and instantaneously
returns to full illumination when needed.
Ardo UK turned to the Titchfield Group to manage the entire
process for upgrading its aging HID lighting, including design,
evaluation, selection and installation. Hands-on during every
stage, the Titchfield team meticulously examined a wide variety
of lighting alternatives before recommending the Digital Lumens
system. In addition to excellent light quality and illumination levels,
they recommended the Intelligent Lighting System for its:
Controllability. Integrated LightRules management software
enables granular control over lighting setting so that the Ardo
team can fine-tune fixture settings, such as timeout and dimming
levels, by zone, individual fixture or system-wide. Because the
fixtures are wirelessly networked, the team does not need to
use a lift to access and manually change dip switches on fixtures;
all changes are made via software.
Insights into how lighting is used and all aspects
of savings. Through LightRules, facility teams gain in-depth
operational insights into how lighting is being used via informative
reports and interactive facility maps. Facility maps show where
lighting use is concentrated within the facility over a specified
period of time, and allow authorized users to interactively
modify settings. With easy access to this data, facility managers
can easily evaluate the lighting metrics, provide measurement
and verification data to their utility, and easily perform what-if
analysis to determine what modifications are needed to ensure
optimal energy usage.
Durability and performance. In addition to being designed
for use in rugged industrial environments, the Digital Lumens
fixtures carry UL and CE listings on the entire fixtures, and a
5-year warranty. LED-based, they can be cycled on/off millions
of times without compromising fixture lifetime or lumen output
and perform exceptionally well in temperature-controlled spaces
where, unlike traditional alternatives, they instantaneously turn
back on to full illumination when needed.
Maintenance-free operation. No re-lamping or re-ballasting
for the lifetime of the installation, and no mercury disposal costs.
Mobile racking, especially in a cold environment, presents unique
challenges for lighting, said Simon Whittle, Head of Lighting and
Innovation for Titchfield Group. Not only are forklift operators
and facility personnel constantly on the move, but the racks are
moving as well. By enabling us to completely control lighting
delivery within the Ardo UK facility, we could fine-tune the system
to address these challenges to a degree we never thought possible.
Trying out different scenarios to optimize lighting was a breeze
and introduced savings that we could never anticipate in a pre-
installation review. Digital Lumens is at least two generations
ahead of its competitors in providing these capabilities and it
shows especially when you look at the quality of the system
and the level of integration.
All Rights Reserved 2012
Digital Lumens Incorporated
Subject to change without notice.
DOC-000119-00 Rev A 10-12
374 Congress Street, Suite 600
Boston, MA 02210
+1 (617) 723-1200
Figure 2: As the racks open, integrated occupancy sensors embedded in
each Digital Lumens high bay LED fxture turn lights on to provide lighting
for forklift operators and facility personnel.
Showcase Facility Incorporates Energy Efficiency
Innovations in all Aspects of its Design
Headquartered in Fort Worth, Texas, Ben E. Keith Foods is the nations
eighth largest broadline foodservice distributor and one of the worlds largest
independent distributors of Anheuser-Busch products. The company operates
six distribution centers distributing in eleven southwestern states, serving
customers that range from white tablecloth and casual dining restaurants, to
hotels, schools, healthcare facilities and other institutional businesses. Offering
more than 20,000 national and exclusive house brands in all broadline
categories, Ben E. Keith consistently leads the market through customer-centric
innovation and an unwavering focus on operational excellence.
To support rapid growth in the southeastern Texas region, the company is in
the process of building a new 475,000-square foot distribution center on an
82-acre site in the Houston metro area. Expected to be operational by 2013, the new
facility incorporates best practice solutions in all aspects of its design and highlights
Ben E. Keiths company-wide commitment to sustainability and energy
efficiency. They range from an underground water retention pond for cooling
the refrigeration system, to specialized cold dock loading areas and crane-
operated aisles, to an ultra-efficient, LED-based smart lighting system from
Digital Lumens.
Familiar with the impacts on facility budgets and refrigeration loads,
the Ben E. Keith management team was determined to find a lighting
solution for its new distribution center that was significantly more
flexible and efficient than the traditional lighting currently deployed in
other company facilities. A solution that, for safety and productivity
reasons, would also deliver higher-quality light levels to facilitate its 24 x 7
warehousing operations.
After a rigorous evaluation of all options, the team found that solution in the
LED-based Intelligent Lighting System from Digital Lumens. Rather than simply
offering incremental improvements, the Digital Lumens system solved a wide
range of lighting challenges that its facilities have been struggling with for decades.
Compared to traditional lighting alternatives, the Intelligent Lighting System in
the new Ben E. Keith facility will:
Dramatically reduce lighting-related energy use. Backed by
performance data from the companys existing distribution centers, the
Digital Lumens system is expected to save the new facility 90% of the
lighting energy versus high-intensity fluorescents, and 75% over plain LEDs
without integrated sensors and software controls.
Achieve consistent performance and durability in all temperature
environments. Unlike traditional lighting, repeatedly cycling fixtures on or
off, dimming or continuous cold temperature operation will not degrade or
otherwise impact the longevity of the Digital Lumens fixtures. For the Ben
E. Keith facility, this means that lights can be routinely turned off whenever
Ben E. Keith Foods Deploys Intelligent Lighting System
in New Texas Distribution Center
Figure 1: Planning the placement of LED-based
intelligent lighting system components.
475,000 f t
24 X 7
TO -40

F (-40

Case Study
Ben E. Keith Foods
a space is unoccupied for a specified period of time, even in
areas where temperatures consistently reach -40F.
Significantly reduce refrigeration loads. By running at a
low wattage, the Digital Lumens system will significantly reduce
the thermal loads placed on its new refrigeration systems, saving
additional energy and shortening refrigeration duty cycles.
Eliminate routine maintenance costs. By eliminating
re-lamping, re-ballasting and other routine maintenance costs,
the Houston-area facility will eliminate those expenses from
the annual operating budgets.
For as long as I can remember, facility lighting has been one
of the cold storage industrys most significant challenges, said
John Fershtand, Director of Fleet Operations and Energy, Ben E.
Keith Foods. So the fact that we can now program our lighting
to automatically turn on, off or dim depending on whats going on
without shortening the life of the bulb or fixture is contrary
to everything weve known. Add the benefits of extremely low
thermal heat loads and better lighting at a fraction of the energy
cost of other forms of lighting and the decision to deploy the
Digital Lumens system was remarkably easy.
In selecting lighting for its new showcase facility, the Ben E. Keith
management team was driven by one unassailable fact: the rapidly
rising cost of energy is a growing liability that can take its toll on
facility budgets. Gaining control of energy use through efficiency
will have long-term impacts on profitability and energy security,
as well as making a meaningful contribution to the companys
sustainability efforts.
So when the management team began evaluating lighting alternatives
for the new distribution center, energy efficiency was at the top
of their agenda. Using existing facility costs as a guideline, this led
them to the following conclusions:
While the up-front costs for traditional fixtures were
lower, the energy savings associated with the Digital Lumens
system were so significant that the payback period was only
marginally extended.
With occupancy sensors built into each fixture (fixtures
are wirelessly networked and centrally managed through
integrated software controls), the Digital Lumens
system offered the highest level of savings, significantly
outperforming other LEDs solutions.
The addition of the system-wide intelligence and reporting
in the LightRules lighting management system will provide
additional insight and control so that the team can better
analyze and adjust lighting settings to meet facility needs and
energy goals.
When you compare the lifetime costs associated with various
lighting alternatives, it becomes immediately apparent that trading
off lower up-front costs for a lifetime of high energy bills really
doesnt make much sense, continued Mr. Fershtand. Beyond being
a very expensive trade-off, it leaves the facility exposed to future
price increases in an era of unpredictable energy markets. Now
that we have a solution that solves so many of our other lighting
challenges, the reasoning behind the Intelligent Lighting System
decision becomes immediately apparent. Its the economically,
fiscally and socially responsible thing to do.
As a showcase for the latest sustainable building technologies, the
new Missouri City facility will expand Ben E. Keiths footprint in
Texas, and show its customers that its commitment to sustainable
business practices extend to all aspects of the operation.
All Rights Reserved 2012
Digital Lumens Incorporated
Subject to change without notice.
DOC-000120-00 Rev A 10-12
374 Congress Street, Suite 600
Boston, MA 02210
+1 (617) 723-1200
Figure 3: Lighting installation in the cold dock.
Figure 2: The installation team unboxes the Intelligent Lighting System.
Occupancy and Daylight Sensing Drive Efficiency Gains
Vector Aerospace Helicopter Services (Vector) is a worldwide leader in
helicopter maintenance, repair and overhaul (MRO), providing comprehensive
support for Sikorsky, Eurocopter, AgustaWestland and Boeing helicopters. Part
of Vector Aerospace, a globally acclaimed provider of MRO services for fixed-
wing and rotary-wing aircraft operators around the globe, its service portfolio
includes support for various types of turbine engines, dynamic components,
structures and avionics, backed by an impressive array of test cell capabilities
and original equipment manufacturer (OEM)-approved programs. From facilities
in Canada, the United States, the United Kingdom, France, Australia and South
Africa, the company provides services to more than 2,000 military, commercial
and private operators in 56 countries.
With an absolute commitment to deliver the highest levels of quality and
workmanship at a competitive price, Vectors management fosters a culture
of process-driven innovation and efficiency in all aspects of its operations.
So when it came to replacing the aging 400 Watt Metal Halide (MH) lighting
at its 158,000-square-foot helicopter MRO facility in Richmond, BC, Canada,
the management team carefully considered all options before moving forward
with a new lighting system.
Vector conducted a thorough review of suitable lighting alternatives, including
fluorescents and plain LEDs, before settling on the Intelligent LED Lighting
System from Digital Lumens. Using the Intelligent Lighting System, Vector is:
Reducing its annual lighting costs by 72%, saving 707,735 kWh annually.
Significantly increasing the intensity of lighting reaching the workstations
that are critical to its operations and the precision work that is at the
center of its business.
Leveraging available ambient daylight to reduce energy use via the systems
integrated daylight harvesting capabilities, which assess the amount of
ambient light and smoothly increase or decrease lumen output to meet
required light levels.
Eliminating the maintenance costs associated with frequent re-lamping and
Facility management was impressed by the durability of the design and the
level of integration Digital Lumens achieved with its occupancy and daylight
sensing capabilities, which are wirelessly networked and managed through the
LightRules lighting management software.
According to John Mellas, Facility Manager for Vector, Before choosing the
Digital Lumens system, we looked at a variety of fluorescent and LED alternatives
with add-on sensors, but the quality and flexibility just were not there. It looked
Vector Aerospace Helicopter Services North America
Saves More Than 72% on Annual Energy Costs
While Gaining Better Quality Lighting
Figure 1: A complete system of smar t high bay LED
luminaires and built-in integrated sensing and controls.
158,000 f t
6 X 20
Case Study
Vector Aerospace
like sensors were an afterthought. The Digital Lumens system
with fully integrated controls and sensing is generations ahead
of competitors. The savings are already adding up, and are
increasing as we fine tune fixture settings to meet our ongoing
operational needs.
There were a wide range of lighting challenges that Vector needed
to solve with the replacement of the 400 Watt MH lighting. Namely,
the legacy fixtures consumed too much energy; could not be
cycled on and off (e.g. slow ramp up times to reach full illumination
when needed, and negative impact on the lamp and fixture
lifetimes); experienced rapid lumen depreciation requiring frequent
re-lamping and re-ballasting; and forced the facility to over-light
space in order to get enough lighting to where it needed to go,
which had the unwelcomed side effect of producing glare and even
higher energy costs.
The Intelligent Lighting System solved all these problems and
more by offering:
A complete system of smart high bay LED luminaires
and built-in integrated sensing and controls. Integrated
occupancy sensors turn off or dim lighting when a space is
unoccupied and instantly back on when needed (off time
extends, rather than reduces, the longevity of LED-based
Fixtures with three independently rotatable LED light bars
that enable Vector to direct light exactly where it is needed,
eliminating glare and the need to over-light.
Integrated LightRules management software that enables
Vector to modify fixture settings and behaviors without
ever touching a light fixture by zone, fixture or facility-
wide. LightRules also provides comprehensive reports
on the operation to take the guesswork out of lighting
performance and optimization.
Interactive Facility Maps that enable Vector to visually
monitor how lighting is being used such as where activity
is concentrated within the facility and percentage of fixture
on time during a specified time interval and fine tune
settings interactively.
Energy savings that accumulate so quickly that they support
a rapid payback, with years of follow-on savings going
directly to the bottom line.
A green solution that makes a significant contribution to
Vectors sustainability agenda.
Vectors HID fixtures were replaced one-for-one with the Digital
Lumens 18,000-lumen intelligent lighting fixtures, which deliver
better, higher output lighting focused on the work surfaces that
are so pivotal to the business. When a workstation is unoccupied,
lighting now dims to 50%. The facility management team plans to
further reduce dimming to 30% over time as employees used
to lighting being on 100% of the time become familiar with the
new system. When the integrated occupancy sensor is subsequently
activated, lighting instantaneously returns to full illumination.
Often, lighting solutions look great on paper, but when you test
them under actual facility conditions, major issues crop up that, if
known in advance, would de facto kill a project, continued John
Mellas. We tested both a fluorescent and an LED alternative, for
example, both of which produced so much glare at the light source
that employee complaints were immediate. This observation would
not have been possible without the on-site test. Obviously, quality
matters and we are thrilled with the results weve achieved with
Digital Lumens.
All Rights Reserved 2012
Digital Lumens Incorporated
Subject to change without notice.
DOC-000121-00 Rev A 10-12
374 Congress Street, Suite 600
Boston, MA 02210
+1 (617) 723-1200
Figure 2: Fixtures assess available light/daylight from open bays and
skylights and adjust output levels accordingly.
Figure 3: Vectors HID fxtures were replaced one-for-one with the
Digital Lumens 18,000-lumen intelligent lighting fxtures, which
deliver better, higher output lighting focused on the work surfaces that
are so pivotal to the business.
Delivers Signifcant Bottom-Line and Carbon Emissions
Savings 93% Less Than Conventional Lighting Alternatives;
Facilitates Demand Response Program Participation
Unlteo States Colo Storage (USCS) ls one ot tbe country's leaolng retrlgerateo
storage ano loglstlcs companles, wltb a customer base tbat lncluoes many
natlonally recognlzeo Amerlcan branos ano lnternatlonal tooo companles.
Tbrougb 34 tacllltles ln 2 states, USCS manages 94 mllllon cublc teet ot
temperature-controlleo warebouse ano olstrlbutlon space, employlng more
tban ,600 servlce protesslonals. Tbe company's mlsslon to provloe blgbly
rellable ano cost-ettectlve loglstlc solutlons tbat enable customers to malntaln
a competltlve eoge permeates tbe USCS culture, resultlng ln a relentless
pursult ot better, more-ettlclent ano sustalnable solutlons to everyoay
buslness cballenges.
Locateo 79 mlles soutbwest ot New York, Hazleton, PA, ls a raploly emerglng
olstrlbutlon bub tor tbe loglstlcs lnoustry ln tbe Nortbeast. To accommooate
growtb, USCS recently completeo an 88,000-square-toot aooltlon to lts
Hazleton taclllty tbat clearly oemonstrates tbe USCS team's tocus on ecellence
ano clear unoerstanolng ot energy's role as tbe slngle largest operatlonal epense
ano CO
emlsslons contrlbutor.
As part ot tbe taclllty oevelopment plan, tbe USCS team loentltleo llgbtlng as a
target area tor energy ettlclency. Tbey stlpulateo a llgbtlng solutlon tbat coulo:
Mlnlmlze per-cublc-toot energy costs, belplng tbe management team meet
or eceeo ambltlous company-wloe etclency ano sustalnablllty goals,
Stano-up to tbe rlgors ot a broao range ot temperature envlronments wltbout
loss ot etclency or negatlvely lmpactlng tbe longevlty ot tbe llgbt ture,
Provloe vlslblllty lnto llgbt usage patterns ano system pertormance, sucb as
workspace occupancy patterns,
Support partlclpatlon ln oemano-response programs, ano
valloate tbe actual kWb use ano enable tuture savlngs opportunltles.
Worklng wltb Groom Lnergy Solutlons, a leaolng provloer ot commerclal ano
lnoustrlal energy solutlons, USCS revleweo a range ot energy-ettlclent llgbtlng
alternatlves tor lts new aooltlon. Atter caretully evaluatlng tbe alternatlve
tecbnologles ano buslness cases, USCS cbose to lnstall tbe LLD-baseo |ntelllgent
Llgbtlng System trom Dlgltal Lumens, wltb game-cbanglng results. Specltlcally,
tbe Hazleton taclllty team successtully:
Acbleveo llgbtlng costs ot just 3.5 per square toot per annum 90 less
tban conventlonal solutlons, wblcb woulo bave cost 46,
Drastlcally cut llgbtlng-relateo CO
emlsslons, to less tban 93 ot tbe levels
ot legacy llgbtlng alternatlves,
vlrtually ellmlnateo cblller-loao costs assoclateo wltb llgbtlng-relateo beat
transter ln temperature-controlleo envlronments,
Lllmlnateo tbe neeo to buoget tor costly re-lamplng ano malntenance epenses
assoclateo wltb traoltlonal solutlons, ano,
Secureo years ot ongolng savlngs wltb payback ot 4.6 montbs.
Case Study
United States Cold Storages New Facility Reduces Lighting-Related Energy
Costs to an Unprecedented Low of 3. 5 Per Square Foot Per Year
Figure : A standard LightRules report shows USCS staff
daily lighting energy use.
United States Cold Storage
!"#$%&'()%* ,-.#/0*#
24 7
Amblent, colo, ano retrlgerateo spaces
4#3"#$%&0$# 5%)6#
20 to 40F
7$#2'(08 9'6.&')6 ,(*0&'()
N/A (new constructlon)
:#; 9'6.&')6 ,(*0&'()
Dlgltal Lumens |ntelllgent Llgbtlng System
7%<=%-> 7#$'(/
4.6 montbs
?))0%* 9'6.& @(8& A B&
3.5 (versus 46 tor a traoltlonal solutlon)
5#8#**#$ 7%$&)#$
Groom Lnergy Solutlons
D&'*'&< 7%$&)#$
PPL Corporatlon, a Pennsylvanla-baseo utlllty
United States Cold Storage
Wblle tbe potentlal tor oramatlc savlngs was tbe orlver tbat
orlglnally sparkeo our lnterest ln tbe Dlgltal Lumens solutlon, lt
was tbe ruggeoness ot lts oeslgn ano unlque oata-orlven approacb to
llgbtlng management tbat tlppeo tbe scales, salo Mlcbael Lyncb, tbe
vlce Presloent ot Lnglneerlng, Unlteo States Colo Storage. Never
betore bave we bao tbls level ot control ano tlelblllty over bow
llgbt ls useo wltbln one ot our tacllltles, nor tbe ablllty to tlnetune
or recommlsslon our llgbtlng systems to meet cbanglng buslness
neeos. |t ls an eponentlally smarter, more ettlclent ano cost-ettectlve
way to manage llgbtlng resources ln large lnoustrlal envlronments.
Tbe Hazleton team was crltlcally aware tbat tbe only way to
conserve energy ano ellmlnate wasteo llgbt was to turn llgbts OFF
ln unoccupleo warebouse space ano back ON lnstantly wben
neeoeo. Untll now, tbls poseo an lmposslble ollemma: most llgbt
sources requlre slgnltlcant warm-up tlme to reacb tull lllumlnatlon
a problem turtber aggravateo by retrlgeratlon. As a result, tbe
taclllty was torceo to lllumlnate most ot lts space 00 ot tbe tlme
baseo on lts 247 operatlng scbeoule.
Tbe |ntelllgent Llgbtlng System trom Dlgltal Lumens solveo tbls
problem by comblnlng LLDs' lnstant ON/OFF ano tull olmmlng
cbaracterlstlcs wltb sensors ano tbe sottware tools necessary to
manage ano control tbese bebavlors. Sultable tor new lnstallatlons
or as one-tor-one replacements tor elstlng legacy tltures, tbese
tools ettectlvely put tbe management team ano taclllty englneers
tlrmly ln control ot bow ano wben llgbt ls useo, ensurlng tbe satety
ano proouctlvlty ot workers.
Among otber capabllltles, tbe Dlgltal Lumens system enables tbe
Hazleton team to manage tlture settlngs tbrougb rule-baseo
sottware controls ln tbe LlgbtRules llgbtlng management system.
Tbe team can speclty at an lnolvloual, group or system-wloe
level olmmlng levels or tbe lengtb ot tlme between a space
belng vacateo ano wben tbe tlture eltber turns OFF or olms to a
specltleo level. |n aooltlon, tbe system collects actlonable oata trom
eacb tlture's lntegrateo occupancy sensor ano power meter ano
generates oetalleo usage reports tor plannlng ano oeclslon-maklng
8y caretully ellmlnatlng wasteo llgbtlng, tbe average ON tlme per
llgbt tlture bas been reouceo to 22.7, resultlng ln oramatlc
bottom-llne savlngs tor tbe taclllty.
A polnt ot prloe wltbln USCS tacllltles ls tbe company's partlclpatlon
ln reglonal oemano response programs, wbereby utlllty companles
pay large customers tor reouclng energy usage ourlng peak oemano
perloos. Known as peak loao sbeoolng, tbe Hazleton taclllty wlll
be tbe tlrst USCS locatlon able to automatlcally reouce llgbtlng-
relateo loaos by actlvatlng a pre-set, user-orlven protlle saveo
wltbln LlgbtRules.
Followlng a peak loao request, tor eample, llgbts ln specltlcally
oetlneo areas may be set to come ON at a reouceo level, say
80 or 90, tor tbe ouratlon ot tbe peak loao perloo, wblcb stlll
provloes sate lllumlnatlon levels tor statt. Aooltlonally, tbe tlme oelay
between a space belng vacateo ano llgbts belng turneo OFF may be
temporarlly reouceo, say trom 60 to 30 seconos, or, olmmlng levels
may be lowereo ln space olrectly aojacent to an occupleo space,
among otber energy-savlng measures.
Hlgbly customlzable, LlgbtRules protlles also provloe tbe Hazleton
taclllty wltb a qulck ano easy metboo ot testlng, re-programmlng
or savlng lnolvloual, group or system-wloe tlture settlngs to aojust
tor cbanglng buslness conoltlons, sucb as seasonal warebouse neeos
or bolloay scbeoules.
For tbe Hazleton team, tbe remarkably low 3.5 per square toot
per annum ln llgbtlng-relateo energy costs represents a major
accompllsbment ano key element ln tbe taclllty's strategy to oellver on
aggresslve corporate sustalnablllty goals. Specltlcally, tbe company's
stateo mlsslon to be 'best-ln-class' by actlvely seeklng out ano
oeploylng more ettlclent ano sustalnable solutlons ls backeo by
target .5 year-over-year reouctlons ln energy use per cublc toot,
tbe prlmary source ot CO
Slgnltlcantly reouclng llgbtlng-relateo energy use ano beat transter
costs amounts to a slgnltlcant strateglc wln tor tbe management
team, resultlng ln llgbtlng-relateo carbon emlsslons tbat are less tban
93 ot tbe levels ot legacy llgbtlng alternatlves. For a company tbat
began bencbmarklng CO
emlsslons at all ot lts tacllltles more tban
tlve year ago, tbe ablllty to collect oetalleo operatlonal oata ano
metrlcs on llgbtlng use pertectly allgns wltb tbe company's goal to
'support strong local management teams wltb tbe tools tbey neeo to
contlnuously lmprove operatlonal pertormance tbrougb tbe ongolng
measurement, oocumentatlon ano sbarlng ot key bencbmark oata.'
Tooay, energy ettlclency ls oeeply rooteo ln tbe corporate culture
at USCS ano tbe |ntelllgent Llgbtlng System trom Dlgltal Lumens ls
playlng lts part ln enabllng tbe Hazleton team to contlnue to meet
or eceeo lts target year-over-year reouctlons, wblle orlvlng tuture
energy ettlclency lmprovements ano operatlonal galns.
Tbe aggresslve pursult ot energy savlngs at tbe USCS Hazleton
taclllty bas resulteo ln wbat once seemeo lmposslble better,
blgber-quallty llgbt at less tban /0tb tbe energy cost assoclateo
wltb traoltlonal llgbtlng systems. |n tbe process, tbe aovanceo LLD
llgbtlng lnstallatlon substantlally contrlbuteo to tbe company's overall
sustalnablllty goals by reouclng lts llgbtlng-relateo carbon tootprlnt
by more tban 93 ln tbe new aooltlon, wblle galnlng a level ot control
over lts llgbtlng system tbat promlses years ot aooltlonal savlngs.

Case Study
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