case studies of energy savings for warehouse lighting with intelligent controls

8/13/2019 CASE STUDIES OF ENERGY SAVINGS FOR WAREHOUSE LIGHTING WITH INTELLIGENT CONTROLS

1/20

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.

LIGHTING CRITERIA DRIVES THE PROCESS

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 metall 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 f loor 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.

LOCATION

New Britain, CT

FACILITY SIZE

140,000 f t2

OPERATIONAL SCHEDULE

Up to 12 x 6

ENVIRONMENT

Manufacturing Facility

TEMPERATURE RANGE

Up to 100F at roof

PREVIOUS LIGHTING SOLUTION

400W HIGH-PRESSURE SODIUM (HPS)

RESELLER

ENERGY SERVICES GROUP

Case Study


2/20

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 of f, 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).

UP TO THE CHALLENGE

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 workstat ions, 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 o

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 set tings at any time through LightRules, withou

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 weekendor 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 alternative

with add-on sensors, they lacked the level of flexibility managemen

required. Additionally, the management team was adamantly againsany 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 canno

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 processWe 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 o

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 09-1

www.digitallumens.com

374 Congress Street, Suite 600

Boston, MA 02210

+1 (617)723-1200

Figure 2: The Creed Monarch facility before (left) and after (right)installat ion of the Intelligent LED Lighting System from Digital Lumens.


3/20

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 networkof 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 lightingneeds 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 andcold storage environments, which range from 70F dry storage areas to 40Frefrigerated spaces to -20F ice cream freezers. They rely on proper lightingto 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 ef ficient and sustainable solution that produced andsubsequently maintained higher levels of quality light, a key driver of safetyand productivity.

Case Study

Maines Paper and Food Service, Inc. Reduces Lighting-Related

Energy Use by 87% in Showcase Facility

Maines Paper andFood Service, Inc.

LOCATION

Conklin, NY

FACILITY SIZE

460,000 ft2

OPERATIONAL SCHEDULE24 x 7

ENVIRONMENT

Ambient, cold, and refrigerated spaces

TEMPERATURE RANGE

-20 to 70F


400W High Pressure Sodium (HPS)

NEW LIGHTING SOLUTION

Digital Lumens Intelligent Lighting System

Figure 1: Before and After

The images above show the original 400W high-pressure sodium fixtures (left), which give

off 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 fixtures 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 requireto fine-tune our system to meet actual, versus

estimated, needs.

The result is a smarter, vastly more efficient

and sustainable solution that puts us firmly in

control of our lighting, today and in the future.

Pat DeOrdio, VP of Operations,

Maines Paper and Food Service, Inc.


4/20

Maines Paper and Food Service, Inc.

EVALUATING THE OPTIONS

The facilities team considered fluorescent fixtures as a possible solution in

both cold and dry spaces. However, to achieve desired light levels, they wouldneed to install 8-lamp high-intensity f luorescents (HIF) at 300W each, whichquickly eroded the potential energy savings and, as a mercury-based light

source, created hazardous waste issues and costs. There were also significantconcerns surrounding fluorescent fixture performance in a cold environment.The search continued.

THE RIGHT SOLUTION FOR DEMANDING INDUSTRIAL APPLICATIONS

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 demandingindustrial applications, the Intelligent Lighting System integrates high-intensityLEDs, 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 its400W 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 energyuse 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.

A BRIGHT FUTURE FOR ENERGY SAVINGS

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. Sincedeployment, 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 (CO2) per year equivalent to removing 200 homes per yearfrom the grid. Those results contribute significantly to the safe and sustainablework 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 20Digital Lumens Incorporate

US and internationapatents pendin

Figure 4: Digital Lumens Intelligent Lighting System uses 89.3%

fewer kWh than alternatives. Data gathered at 15-minute

intervals from a 400W HID fixture, a 300W fluorescentalternative, and the Digital Lumens system shows cumulative

energy use in a 24-hour period. The Digital Lumens fixture

enters a true standby mode and consumes zero powe

whenever an aisle or work area is vacant and uses only

1.2 kWh/day. The HID fixture must remain ON to ensure

immediate light delivery (11.96 kWh/day). The fluorescen

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.

0

50

100

150

200

250

300

350

400

450

500

19:58:53

20:28:53

20:58:53

21:28:53

21:58:53

22:28:53

22:58:53

23:28:53

23:58:53

00:28:53

00:58:53

01:28:53

01:58:53

02:28:53

02:58:53

03:28:53

03:58:53

04:28:53

04:58:53

05:28:53

05:58:53

06:28:53

06:58:53

07:28:53

07:58:53

08:28:53

08:58:53

09:28:53

09:58:53

10:28:53

10:58:53

11:28:53

11:58:53

12:28:53

12:58:53

13:28:53

13:58:53

14:28:53

14:58:53

15:28:53

15:58:53

16:28:53

16:58:53

17:28:53

17:58:53

18:28:53

18:58:53

19:28:53

AveragePower(Watts)

Time of Day

Average Power Consumption

HID

HIF

DL

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


5/20

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 findcustomer-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.

CUSTOMER EXPERIENCE REIGNS SUPREME

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 bothin 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 Eff iciency 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.

ENVIRONMENTRetail grocery, ambient, and refrigerated spaces

TEMPERATURE RANGE

65to 75F


400 W metal halide

SHIFTS

3 shifts x 7 days

ANNUAL LIGHT COST / FT2

3.5 (versus 46 for a traditional solution)

RESELLER

Leading Edge Design Group

UTILITYPARTNERBurlington Electric Department (BED)

Case Study

Burlington, VT 16,000 ft2facility


6/20

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.

EXTRAORDINARY SAVINGS REQUIRES INTELLIGENCE

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 furtherefficiency 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.

SUCCESS ON ALL FRONTS

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 definit ion of project success!"

Case Study

Figure 2: Digital Lumens LED fixtures improve lighting

quality throughout the City Market retail environment.




DOC-000053-00 Rev A 08-1


110 Canal St, 7th Floor

Boston, MA USA 02114

+1 (617)723-1200


7/20

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 Englandwas 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 thenations largest retailer-owned purchasing and distribution cooperatives,

serving more than 600 independent food stores throughout New Englandand Upstate New York.

In addition to providing retail support services, AG New England operates

a 380,000-square foot warehousing and distribution center, which employsmore than 300 service professionals in areas ranging from advertising and

marketing to merchandising and warehousing operations. This best practicefacility 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 facili ty in the country, however,AG New England has wrestled with the high energy and maintenance costsassociated 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 ef ficiency and cost containment goals, the managementteam at AG New England was determined to find a safe, no-compromise

lighting solution for its cold storage warehousing area.

DIGITAL LUMENS OPENS THE DOOR TO SIGNIFICANT SAVINGS

Working with the Leading Edge Design Group (LEDG), an energy optimization

services firm offering lighting design and consultation services, AG NewEngland evaluated its options. The challenge was to find a one-for-one

replacement alternative for its T5 HO lighting fixtures located within a56,600 -square foot cold storage area . Mainta ined 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'ssustainability goals.

Following a thorough review, LEDG recommended replacing the facility's

fluorescent fixtures with the LED-based Intelligent Lighting System fromDigital Lumens. By incorporating smart, LED fixturesall with built-in

occupancy sensors, wireless networking and software controlstheIntelligent Lighting System offered AG New England a clear path to unmatched

energy eff iciency 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 ofNew England (AGNE)

LOCATION

Pembroke, NH

FACILITY SIZE

380,000 ft2with 56,000 ft2cold storage

lighting upgrade from Digital Lumens


24 x 6

ENVIRONMENT

Refrigerator

TEMPERATURE RANGE

-15 F


T5 HO fuorescent

SHIFTS

3

RESELLER

Leading Edge Design Group (LEDG)

UTILITYPARTNERPublic Service of New Hampshire

Case Study


8/20

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 levelsand quality.

For years, lighting our cold storage areas has been fraughtwith challenges, ranging from durability and efficiency issues,

to heat dissipation and its impact on refrigeration loads, saidBruce 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 per formance and evaluation metricsthe LEDG team also managed the process of securinga utility company incentive. The cooperatives utility company, Public Service of New Hampshire, contributed to the installationcosts associated with replacing aging lighting systems through its NHSaves@Work/Large Business Energy Solutions Program.

HISTORICAL PERSPECTIVE ON AG NEW ENGLANDS LIGHTING

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 environmentswith 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 asneededturned 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, eliminatingthe 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 alighting fixture.

Access to detailed light usage and occupancy reports that document how lighting is used within the facility, providing theinformation 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 andsignificant bottom-line savings.

Case Study

Figure 2: Digital Lumens LED fixtures improve lighting

quality throughout the AGNE warehouse environment.

All Rights Reserved 2012Digital Lumens Incorporated

Subject to change without noticeDOC-000092-00 Rev A 06-1

www.digitallumens.com110 Canal St, 7th FloorBoston, MA USA 02114+1 (617)723-1200


9/20

Chicago-Area Warehouse Management CompanyReduces 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 2of 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 ft2unheated facility that

operates on a 24x7 basis year-round, the search for a new solution was wide-ranging

and exhaustive.

MANY CHALLENGES, ONE SOLUTION

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.

SAVINGS ON TOP OF SAVINGS

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

LOCATION

Chicago, IL

FACILITY SIZE

177,413 f t2


24 x 7

ENVIRONMENT

Ambient Warehouse


1000W Metal Halide

SHIFTS

3

RESELLER

Green Light

UTILITYPARTNER

ComEd

Case Study


10/20

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 arapidly 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 eachtime 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.

INTELLIGENT LEDS VERSUS FLUORESCENTS

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% fosecurity 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 fu

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 granula

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 af ter 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 managemen

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 settingsto accommodate changing operationaneeds. 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

electric ians, 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 importan

component of our strategy to offer tenants superior solutions tha

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 firm that helps tenants and

property owners reduce the operating expenses associated with energy

consumption by taking advantage of the technological advances in

efficient lighting, environmental controls, and building envelope efficiency

(www.greenlightnational.com).


Digital Lumens Incorporate


DOC-000102-00 Rev A 07-12




+1 (617)723-1200


11/20

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) isthe oldest cold storage company in North America and remains, to this day, dedicatedto providing flawless and efficient storage and logistics services to its worldwidecustomer base. In addition to enabling the movement of dry, time and temperature-sensitive cargoeither by truck, rail, container ships or breakbulk cargo vesselsthe company operates 4 warehousing facilities in three strategic U.S. port cities,

including New Orleans, Houston and Charleston, with more than 12,000,000 cubicfeet of refrigerated storage capacity.

In the aftermath of Hurricane Katrina, New Orleans Cold Storage decided to build anew 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 extraordinaryopportunity to re-think how energy was used, and zeroed-in on energy ef ficiency as the

driving force for capital investment decisions. Traditional lightingincluding the heatit generates and corresponding impact on freezer loadswas specifically targeted forimprovement, as it consistently represented one of the highest line items in the originalfacilitys budget (after refrigeration). Lighting simply consumed too much energy andrequired too much maintenance, which would place an undue burden on the facilitysbudget and warehousing operations.

Working with Primus Design Services and The McDonnel Group, a constructionmanagement company, the team at NOCS was determined to find a dramaticallymore efficient, maintenance-free lighting solution to support the locations poultrybusiness. It found that solution and more with the Intelligent LED Lighting Systemfrom Digital Lumens.

To say lighting has always represented a challenge for our cold storage facilities wouldbe an extreme understatement, said Mark Blanchard, President of New OrleansCold Storage. From fixture longevity and heat loads, to lamp life, maintenance andefficiency, 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 controlwithoutthe disruptions associated with regularly changing burned out bulbs and ballasts.

REAPING TREMENDOUS SAVINGS

The new cold storage warehouse, with 40-foot ceilings, has temperatures that rangefrom -15F for its three Quick Freezing Rack rooms (which can freeze more than560,000 pounds of poultry to 0F within a 24-hour period), to -10F for large openstorage space, and 35F for dock areas used for loading and unloading cargo. The DigitalLumens highbay product lineavailable with either narrow optics (for racked aisles)or wide optics (for distributing light evenly over open spaces) opticsaddressed thevarying needs of the facility while:

Saving more than 245,764 kWh in annual energy use, or 60% less than the 6-lampT5 high-intensity f luorescents 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 ORLEANSCOLD STORAGE

LOCATION

New Orleans, LA

FACILITY SIZE

142,000 ft2

ENVIRONMENT

Cold Storage

TEMPERATURE RANGE

-15 to 35F

ALTERNATIVE LIGHTINGSOLUTION CONSIDERED

6-lamp T5 HIF

SHIFTS

2

DESIGN FIRM

Primus Builders

www.primusbuilders.com

GENERAL CONTRACTOR

The McDonnel Group

www.mcdonnel.com

Case Study


12/20

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 thelow-wattage, occupancy-driven place on the refrigeration system.

We evaluated a range of industrial LED lighting alternativesand 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 enhancequality and performance of critical infrastructure, while reducingthe energy intensity of the project .

UP TO THE CHALLENGEIn the new facility, which offers 4.3 million cubic feet ofstorage, NOCS installed three state-of-the-art Quick FreezeRack Zones (QFRs) freezers that are maintained at -15F.

They use a high-powered air-movement system that circulates cold

air to more cost effectively chill the chicken, helping the facilityuse 1/3 the horsepower of comparable facilities.

Adding to the very real energy savings is the Intelligent LightingSystems unique range of features and benefits, which are enablingthe 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 Lumensfixtures instantly return to full brightness when the sensor isactivated, even in the extremely cold QFR areas .

Have detailed operational reports. LightRules, the DigitalLumens lighting management software, wirelessly gathers datafrom every fixture and provides reports showing energy useor occupancy by room, shift or facility-wide so that the NOCS

engineering team can optimize lighting settings and respond tochanging operational needs.

Easily modify and optimize fixtures settings without

ever having to touch them. With LightRules, the NOCSteam can easily modify lighting settings via the keyboard, sothey never need to use a scissor lift to make changes.

Eliminate maintenance and mercury disposal feesTraditional HIF lamps require frequent re-lamping and reballasting, particularly when used in cold environments or

cycled on and off to save energy, which significantly decreasesfixture life. With the Digital Lumens system, NOCS eliminatedmaintenance costs altogether.

Reduce thermal load on the chiller system. The 160-Wat

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 opticsfrom narrow for task lighting to wide for broad and evendistributionthe Intelligent Lighting System provided NOCSwith the flexibility to match fixture choices to the specificneeds of its facility.

Unveiled at a ceremony in New Orleans attended by Louisiana

Governor, Bobby Jindal, and other local officials, supplementafunding for the project was provided by the U.S. Army Corps oEngineers, the Port of New Orleans, and the State of LouisianaAccording to Mark Blanchard, President of New Orleans ColdStorage, The Digital Lumens System is delivering everything weexpected and moreenergy efficiency, light quality and costcontainment perspectivehelping ensure success for the company

the environment, and the great State of Louisiana.


Digital Lumens Incorporate


DOC-000103-00 Rev A 07-12




+1 (617)723-1200

Figure 2: Intelligent LED lighting in the QFRs provides light where andwhen needed.

Figure 3: From the very start of the project, company managemenrecognized that the rebuild presented an extraordinary opportunity tore-think how energy was used, and zeroed in on energy efciency as thedriving force for capital investment decisions.


13/20

Eliminates 427.7 Metric Tons of CO2and

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 gif ts of nature for customers

and consumers a commitment to qualit y 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.

FLEXIBLE LED LIGHTING DRIVES UNPARALLELED SAVINGS

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 CO2over 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 largeareas 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 Digita l Lumens system all these problems went away. We now have complete

control over our lighting, better light qualit y, 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 m3Ardo facility in Kent, UKserves customers in the retail, foodservice and

industrial ingredients markets under its own brandor under customer trade labels.

LOCATION

KENT, UK

FACILITY SIZE

80,000 m3


24/6

ENVIRONMENT

BRC-CERTIFIED COLD STORAGE

TEMPERATURE RANGE

-27to -22C (-17to -7F)


400W HID, POWERED ON 24/7

RESELLER/INSTALLER

TITCHFIELD GROUP

HERTS, UK

Case Study

Ardo UK


14/20

ARDO UK Case Study

ARDO UK LIGHTING REQUIREMENTS

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 morethan 30 seconds, the lighting turns off until a sensor is reactivated

by a forklif t 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 softwareenables 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 outpu

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-ballastingfor 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.




DOC-000119-00 Rev A 10-12



Boston, MA 02210

+1 (617)723-1200

Figure 2: As the racks open, integrated occupancy sensors embedded ineach Digital Lumens high bay LED fxture turn lights on to provide lightingfor forklift operators and facility personnel.


15/20

Showcase Facility Incorporates Energy E fficiency

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 largestindependent distr ibutors 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-centricinnovation and an unwavering focus on operational excellence.

To support rapid growth in the southeastern Texas region, the company is inthe 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 coolingthe refrigeration system, to specialized cold dock loading areas and crane-

operated aisles, to an ultra-efficient, LED-based smart lighting system fromDigital Lumens.

SOLVING DECADES-OLD LIGHTING CHALLENGESFamiliar 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, theDigital Lumens system is expected to save the new facility 90% of the

lighting energy versus high-intensi ty 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 wi ll not degrade orotherwise impact the longevity of the Digital Lumens fixtures. For the BenE. 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-basedintelligent lighting system components.

LOCATION

MISSOURI CITY, TX

FACILITY SIZE475,000 ft2


24 X 7

ENVIRONMENT

COLD, AMBIENT STORAGE

TEMPERATURE RANGE

TO -40 F (-40 C)

INSTALLATION TYPENEW CONSTRUCTION

Case Study

Ben E. Keith Foods


16/20

BEN E. KEITH FOODS Case Study

a space is unoccupied for a specified period of time, even in

areas where temperatures consistently reach -40F.

Signif icantly 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 fromthe annual operating budgets.

For as long as I can remember, facility lighting has been one

of the cold storage industrys most significant challenges, saidJohn Fershtand, Director of Fleet Operations and Energy, Ben E.Keith Foods. So the fact that we can now program our lightingto 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 lowthermal heat loads and better lighting at a fraction of the energy

cost of other forms of lighting and the decision to deploy theDigital Lumens system was remarkably easy.

THE ENERGY EFFICIENCY CALCULATION

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 onfacility budgets. Gaining control of energy use through efficiencywill have long-term impacts on profit ability 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 ledthem to the following conclusions:

While the up-front costs for traditional fixtures werelower, the energy savings associated with the Digital Lumenssystem were so significant that the payback period was onlymarginally extended.

With occupancy sensors built into each fixture (fixturesare wirelessly networked and centrally managed throughintegrated software controls), the Digital Lumenssystem offered the highest level of savings, significantlyoutperforming other LEDs solutions.

The addition of the system-wide intelligence and reportingin the LightRules lighting management system will provideadditional insight and control so that the team can betteranalyze and adjust lighting settings to meet facility needs andenergy goals.

When you compare the lifetime costs associated with variouslighting 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-of f, it leaves the facility exposed to futureprice increases in an era of unpredictable energy markets. Nowthat we have a solution that solves so many of our other lightingchallenges, 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.




DOC-000120-00 Rev A 10-12



Boston, MA 02210

+1 (617)723-1200

Figure 3: Lighting installation in the cold dock.

Figure 2: The installat ion team unboxes the Intelligent Lighting System


17/20

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 SouthAfrica, 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.

LOTS OF CHOICES, ONE SOLUTION

Vector conducted a thorough review of suitable lighting alternatives , includingfluorescents 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 andre-ballasting.

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 f luorescent 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 smart high bay LED

luminaires and built-in integrated sensing and controls

LOCATION

RICHMOND, BC, CANADA

FACILITY SIZE

158,000 f t2


6 X 20

SHIFTS

2

ENVIRONMENT

MRO FACILITY

TEMPERATURE

AMBIENT

INSTALLATION TYPE

RETROFIT


400 WATT METAL HALIDE (MH)

Case Study

Vector AerospaceHelicopterServices


18/20

VECTOR AEROSPACE HELICOPTER SERVICES Case Study

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.

THE DIGITAL LUMENS RECOMMENDATION

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).

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 timebecome 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 tes

them under actual facility conditions , major issues crop up that, i

known in advance, would de facto kill a project, continued JohnMellas. 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.




DOC-000121-00 Rev A 10-12



Boston, MA 02210

+1 (617)723-1200

Figure 2: Fixtures assess available light/daylight from open bays andskylights and adjus t output levels accordingly.

Figure 3: Vectors HID xtures were replaced one-for-one with theDigital Lumens 18,000-lumen intelligent lighting xtures, which

deliver better, higher output lighting focused on the work surfaces thaare so pivotal to the business.


19/20


20/20

United States Cold Storage

iV3#-% $3% 9,$%"$#)- 2,. &.)8)$#4 *)H#"/* ;)* $3% &.#H%. $3)$

,.#/#")--6 *9).Z%& ,5. #"$%.%*$ #" $3% X#/#$)- L58%"* *,-5$#,": #$

;)* $3% .5//%&"%** ,2 #$* &%*#/" )"& 5"#]5% &)$)E&.#H%" )99.,)43 $,

-#/3$#"/ 8)")/%8%"$ $3)$ $#99%& $3% *4)-%*:j *)#& `#43)%- L6"43: $3%

a#4% [.%*#&%"$ ,2 M"/#"%%.#"/: !"#$%& ($)$%* +,-& ($,.)/%? iO%H%.+QLQ@R ![( @JM >O@M

@3% )//.%**#H% 95.*5#$ ,2 %"%./6 *)H#"/* )$ $3% !(+( J)=-%$,"

2)4#-#$6 3)* .%*5-$%& #" ;3)$ ,"4% *%%8%& #89,**#-- T#/3$* T%*%.H%& m CGX#/#$)- L58%"* Q"4,.9,.)$%

!( )"& #"$%.")$#,")9)$%"$* 9%""

case studies of energy savings for warehouse lighting with intelligent controls

Documents