Welcome to the first in a series of lighting retrofit case studies we will be publishing in the coming months.  In this series, we highlight customers in various industries that have gone through a lighting retrofit in their facility to take advantage of more energy-efficient technology.  This lighting retrofit case study can be used as an example of what is attainable via a lighting retrofit by those interested in undergoing similar retrofit projects.  If you have a facility type that we have not covered, please feel free to leave a comment or contact us.  We have been involved in many lighting retrofit projects and may be able to call upon our previous clients for specific data needed for a case study.

Company Background

Innovative Packaging produces all types of corrugated packaging products and serves the Indiana, Michigan and Ohio markets. The company designs all products to customer specifications and can take projects from conception to a final corrugated piece delivered to the customers location. That final product may be a printed or labeled carton, point of purchase display with graphics, or any number of specialty die cuts.

The Opportunity

Innovative Packaging operates out of a 118,800 square foot facility that is used for both production and warehousing.  Prior to the lighting retrofit, the facility was predominantly lit with 400 W Metal Halide fixtures.  Light levels were very low throughout the area so the company had also installed 4' and 8' T12 Linear Fluorescent strips over work areas to improve the light levels where needed.

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As part of a company-wide initiative to combat rising energy costs, Lear Corp (NYSE:LEA) has begun the installation of new energy-efficient plant lighting in more than 1 million square feet of manufacturing and warehouse space in five of it’s facilities in Mexico and Honduras. The lighting retrofits will deliver more than $3.1 million in electrical savings over the next five years and eliminate more than 4.8 million tons of carbon emissions per year.

The plants, which are required to purchase electricity from the local government-owned utilities, are paying up to $0.14 per kilowatt hour for power. The more efficient T5 lighting system has allowed them to reduce their energy needs and has also led to improved safety, security and worker satisfaction.  Lear expects the project will pay for itself in less than twelve months.

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Like many smart companies, cost-control is of paramount importance to Innovative Packaging.  That’s why the Company has completed a $35,000 project to retrofit all of the high bay lighting in its 115,000 square foot facility with energy-efficient T5 fluorescent fixtures from Electrical Marketplace. By doing so, Innovative Packaging will lower operating costs associated with lighting by more than 46%.

Innovative Packaging was able to reduce its energy demands by more than 128 Megawatts per year by replacing all of the aging and costly 400 Watt metal halide fixtures with new, energy-efficient T5 fluorescent high bays.  This switch will prevent the emission of more than 147 tons of greenhouse gases into the atmosphere.  The new fixtures provide better quality light and are expected to improve productivity and warehouse safety.

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