Case Study: Industrial Facility Decreases Downtime and Maximizes ROI

Aug 1, 2017

Situation

The world’s leader in high technology batteries for industry and specialized applications was ready to retrofit their lighting fixtures in one of their 19 worldwide facilities. The company had burn outs throughout the facility, which caused them to have inaccurate lighting levels. Additionally, the production area was looking to retrofit their current lighting system so they could enhance their workforce productivity by decreasing downtime due to maintenance on lighting fixtures. That’s when the company began looking at TCP Lighting. They not only needed uniformity of illumination, but they also needed a cost efficient lighting solution. They needed to maximize their ROI while decreasing facility downtime.

Solution

The shop area was lit by 400 watt metal halides. Replacing the metal halides with LED fixtures helped the facility to have significant energy savings in addition to balancing the light distribution. Maintenance on lighting in industrial applications can get pricey, because it can consist of many workers and potential overtime to avoid production downtime. That’s why TCP replaced their metal halides with 24,000 lumen Sky Bays. Before utility rebates, the company is projected to save an estimate of $54,662.40 in energy savings over the life of the product.

It was very important for the industrial facility to have long lasting product to decrease the amount of time and money spent on labor and maintenance. A good indicator for how long a lighting product will last is to review the lumen maintenance calculation, which you can find in the product’s specifications. Manufacturers will mark their luminaires with a rated life, which is an acceptable amount of delivered lumens for a certain amount of time. TCP’s Sky Bays have a rated life of 50,000 hours. Not only did the facility save money because of energy savings, but they also saved by collaborating with TCP’s utility rebate team and re-evaluating their current lighting layout.

Because of this installation, we have faster run-up times, decreasing production delays. We’re very happy with the time TCP took to understand our business and to help us meet our facility’s need for little to no downtime.

Maintenance Manager

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