Lighting and Energy Management
Client is a manufacturer of hydraulic systems and components with more than 90 years experience
supplying hydraulic components for mobile, industrial, marine, and other applications to top companies
around the world.
Challenge/Opportunity
Client had manufacturing facility filled with (155) old 400 Watt Metal Halide fixtures that were installed
in the 1970’s. These fixtures had their day, but technology had advanced to where these products were costing
thousands of unnecessary dollars to operate. The energy cost of burning these metal halides was negatively
affecting their bottom line.
Solution
FRG met with Client’s facilities management team and discussed their energy saving objectives. Lighting was
discussed, and through the course of the conversation they started to see the huge opportunity presenting them.
Once this potential was realized, Client recognized that they could improve their lighting quality, color
rendering, longevity of lamps and, at the same time, reduce their energy costs by almost half. They immediately
initiated an FRG Lighting Audit. Once the audit was completed and the savings potential was verified, the
capital project was approved. Further planning took place as to how this project was going to be completed.
Client couldn’t have any interruption to their operations while project was executed and had to be seamlessly
coordinated with each of their departments. FRG worked closely with Client’s operations and department managers
to successfully put together a plan that met everyone’s approval. The lighting retrofit took two weeks to
complete and turned out even better that expected. Client’s staff enjoyed the lighting transformation and
positive comments are still coming.
Results
Client realized a 2.1 year ROI factoring energy cost savings alone along with the following benefits:
- Improved Lighting - The color rendering (CRI) ability of the lighting source to show color in its
truest form was increased by 25-30%. The T5 lamps will also last up to twice as long (35,000 hours @ 12
hrs /start), reducing replacements costs. The lamp lumen depreciation (loss of light level) is
significantly less with the T5 fluorescents (8%) than the metal halides (45%).
- Employee Moral/Productivity Increases – There’s been a noticeable increase in manufacturing personnel
moral due to better lighting. Workers who spend their time in poor and/or uneven levels of light can be
easily frustrated in process of completing their tasks. Therefore, as a result, productivity has increased
due to a better illuminated environment.
- Accuracy - Client employees are consistently performing to a higher degree and are making less operational
errors. These errors can prove costly to business when analyzing the rework dollars and loss of sales due to
poor customer service.
- Safety - Workplace safety has improved with improved lighting. Client knows their worker’s
compensation rates are predicated on their safety record and recordable accidents.
- Immediate Light – Fluorescent, unlike HID, lighting will illuminate immediately when power is switched
on. In the event there’s a temporary power outage, the lights will come back immediately when power comes
back and not have to cool off and re-strike.