Lighting Retrofit Project Case Study
October 2012, Sumner Distribution Center
Case Study Series
Case Study Series
Executive Summary
The Mission Produce Lighting Retrofit Project was designed to implement all qualified LED solutions while
realizing maximum financial savings for the client. 93% of the project was retrofitted with LED products
while the 7% was replaced with better performing fluorescent technology. Rather than a high cost central
control system, localized controls were implemented to maximize the energy savings. This project
created 79% energy savings from the previous lighting design & achieved a superior lighting environment
for all worker activities. Simple payback based on electricity alone is 1.4 years and if the additional
savings from maintenance, tax deduction benefit & cooling load reduction are considered, the actual
payback is expected to be within one year from the date of project completion.
Project Introduction
There are three main parts to this project:
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PART I: !
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Refrigerated Warehouse - 48 units of 400W Metal Halide High Bays were !
replaced with 160W LED High Bay with localized controls.
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PART II:!
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Office Area - Task Ambient Lighting Strategy was implemented to create energy saving while
improving worker productivity in the office areas while restrooms and storage rooms
were retrofitted with LED low bay fixtures with motion sensor. All fixtures were controlled with
daylight harvesting, dimming, timers and/or occupancy sensors.
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PART III:!
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Due to high humidity, the current T5HO vapor tight fixtures were left in place and relamped
with low watt T5HO’s, maintaining light levels and increasing efficiency by approximately 10%.
This case study doesn’t cover the T5HO installation.! !
PART I:
Refrigerated
Warehouse
PART II:
Office Area
PART III
Ripe
Rooms
Sumner Distribution Center
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Case Study Series
1.0 Refrigerated Warehouse
400W MH
LUNA 160
Model
400W MH
Model
LUNA 160
Power Usage
455W
Power Usage
160W
Controls Savings
Average of 46%
Total Power Per Unit
86W
Savings Per Unit
Up to 460W
(84% Maximum)
Number of Units
48
Color Rendering Index
83
*Refrigerated Space Interaction
Factor(Where Applicable)
1.2
Total Power Per Unit
546W
Number of Units
48
Color Rendering Index
65
Impressive uniformity with maximum
illumination of work areas with minimal glare.
Much of the light is lost before reaching the
task area and lacks uniformity.
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Case Study Series
1.1 Visual Observations After Retrofit
Superior Heat Sink Design
Minimal heat creation to achieve
dramatic cooling load reduction
Glare-Free
Optical Design
Better Vertical Uniformity & Less Contrast
Quadrupled Light-level
on Task Areas
No-glass
breakage
concerns & no
Mercury
No More 1000W
Halogen Work Lights
Improved Color Rendering Index
Uniform Distribution on the Ground Level
Utility Rebate Eligibility
Design Lights Consortium Qualified Product for maximum eligibility
IES Footcandle Recommendation
Before retrofit light level was at 20 FC(Meets IES Recommendation for medium active
application). After retrofit light levels are measured between 90 - 120 FC.
Productivity Improvement
Higher efficiency is expected in all applications with superior lighting environment. Old
lights had the restrike time of 15 minutes for employees to turn the lights on.
O&M Saving
Controlled LED in a refrigerated environment is expected to last longer. For this
application, 70,000+ hours/L70 expectation is projected.
EPACT 2005 Tax Benefit
Eligible to receive commercial lighting tax deduction benefit.
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Case Study Series
1.2 Controls Integration
Every Lighting Fixture was integrated
into a controls strategy for the Mission
LED Retrofit Project
“The significance of the Mission project is that all
areas and all fixtures are effectively controlled using
a variety of technologies and strategies to insure
maximum energy efficiency without compromising
employee safety and productivity”
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Rick Allen, Energywise
Zone based occupancy control was designed into
the project by Rick Allen, who is the principal of
Energywise. Since LUNA 160 was able to deliver
twice as many footcandles than before with just
half of the units turned on, Rick limited the auto-on
feature to only 50% of the installed high bays in
areas where coverage was appropriate. This
strategy was applied to 46% of the fixtures and
saved an additional 24% annual kWh. This still
met the most aggressive IES recommendation for
warehouse activities. However, since Mission
Produce requires higher light level for certain
activities, he wired the remaining units to a timer
switch so the maximum usage of the lighting will
be limited to applicable activities only.
“Definitely better lighting for productivity,
safety, cleaning & inspection.”
Zura Goodpaster, Distribution Center Manager
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Case Study Series
2.0 Office
Awarded by NGL 2012(www.ngldc.org), the first CCT tunable LED troffer, GP300TK45W and Commercial
Energy Star Certified Prism TL-4300 implements the Task Ambient Lighting Strategy.
3-F32T8
Prismatic Troffer
Model
3-F32T8
Ambient Model
GP300TK45W
Power Per Unit
90W
Power Usage
45W
Number of Units
2
Controls Savings
30%
LPD
1.2 W/SF
Actual Usage Per Unit
31.5W
Total Usage Per Office
180W
Task Lighting Model
TL-4300
Controls
None
Task Lighting Usage
8.5
Task Lighting
N/A
Total Usage
40W
Lighting Design Strategy
None
Saving %
85%
Glare Control
None
New LPD
0.23W/SF
Ambient Light Level
40 - 50 FC on Task Level
across the whole area
Ambient Light Level
Average of 25 FC
Task Lighting Level
50 - 100FC
50FC
50FC
25FC
60FC
180 Watts
40 Watts
Serious Glare Issue
Ergonomic Lighting
*Each of the office area has different level of demand savings. Above comparison was made based on the task ambient lighting model that was implemented for the
private office application.
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Case Study Series
2.1 Visual Observations After Retrofit
Two 3L-F32T8 Troffers
Replaced with One LED
2x2 Troffer
50-100FC Task
Lighting is Provided
by TL-4300
25FC Ambience at Task Level
Minimizes Glare on Monitor Screens
Multiple Custom Mood Settings
for Conference Rooms
3000K
Photosensor
controlled Ambient
Lighting for Lobby
with Daylight
4000K
5000K
User friendly touch control panel for CCT tuning & dimming
Utility Rebate Eligibility
Energy Star & DLC Qualified Product for maximum eligibility
IES Footcandle Recommendation
Meets the code with superior user experience
Productivity Improvement
Higher efficiency is expected in all applications with superior lighting quality
O&M Saving
No maintenance is expected over next 10 years(5 Year Warranty).
EPACT 2005 Tax Benefit
Eligible to receive commercial lighting tax deduction benefit.
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Case Study Series
3.0 Restroom
3 restrooms were retrofitted with A2W4-0445 and wall mounted occupancy control unit.
2-F32T8
1x4 Wraparound
A2W4-0445
Model
2-F32T8
Model
A2W4-0445
Power Usage
59W
Power Usage
46W
Controls
None
Controls Savings
30%
Total Power Per Unit
59W
Total Power Per Unit
32W
Number of Units
3
Savings Per Unit
27W
Color Rendering Index
80
Number of Units
3
CCT
3500K
Color Rendering Index
86
CCT
4500K
Chain or pendant mounting options
are also available for utility lighting
applications.
Surface mounted A2W4-0445 brings
crisp illumination with instant on
feature
Utility Rebate Eligibility
Energy Star & DLC Qualified Product for maximum eligibility on LED solutions.
IES Footcandle Recommendation
Meets the code with superior user experience
O&M Saving
No maintenance is expected over next 15+years on LED applications(5 Year Warranty).
EPACT 2005 Tax Benefit
Qualified under the building area method.
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Case Study Series
Project Management Team:
Project Manager
Rick Allen, Energywise
Strategic Solutions Manager
Ryan Kim, PLANLED
Mission Distribution Center Manager
Zura Goodpaster, Mission Produce
Partner Relationship Manager
David Kim, PLANLED
PSE Engineer
Corey Corbett, PSE
Project Analysis
Simple Payback Based on Energy Savings
Overall Energy Savings
Estimated Annual Energy Savings
Applied Rebate Program
EPACT 2005 Commercial Lighting Tax Deduction
1.4 Years(After Utility Rebate)
79% Energy Saving
147,982 kWh/yr
PSE Enhanced Lighting Program
Eligible to receive commercial lighting tax deduction
benefit
Lighting Design Strategy
Task Ambient Lighting Strategy, Zone Based Occupancy
Controls Strategy
Product Qualification Standard
Energy Star, Design Lights Consortium & Lighting Facts
Ergonomic Lighting Improvement
Greater efficiency and visual comfort have been reported
by the employees
Special Thanks to:
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