New Fixture *Minimum
Annual Operating Hours = 1,500*
LED Exit Signs
14 W and greater LED
LED or Induction HE Exterior
LED or Induction HE Exterior
LED or Induction HE Exterior
LED or Induction HE Garage
LED or Induction HE Garage
LED or Induction HE Garage
Rebate per
Item
$14
$18
$18
$28
$49
$42
$65
$111
was considered waste heat. He divided
that difference by how much it cost to
remove that heat.
“We found that the rough rule of
thumb was that about a third of the actual electricity savings is returned again
in cooling,” Duveneck said.
“So ... doing the math on that, we
could realize several thousand dollars
of savings just in electricity and maintenance alone.”
Item
60
61
62
63
64
65
66
67
Figure 5
Not only did the food manufacturer realize electricity savings, it qualified for a $111 per
fixture utility rebate. Source: http://dom.com/dominion-virginia-power/customer-service/
energy-conservation/pdf/va-lighting-rewards-rebate-chart.pdf.
Replaces
Standard Exit Sign
51W & greater lamps
<175W HID
175-250W HID
250W-400W HID
<175W HID
175-250W HID
250W-400W HID
Wave received a rebate of $111 per
fixture on 230 fixtures it replaced in the
warehouse, as well as additional retrofits it made earlier, for a total of roughly
$40,000 (see Figure 5).
“We had not factored this into our
savings calculations for the lighting project because we were not sure how easy
the rebate would be to get, but it turned
out to be a relatively painless process,”
Duveneck said.
Low Maintenance Has Long Reach The electricity savings alone are not the main benefit, though, Duveneck said. Accessing the lighting above the produc- tion equipment is difficult, and replac- ing the bulbs requires using rental lift equipment, which compounds the cost. Although the electricity cost savings are impressive, the greatest savings came as a result of the low mainte- nance, Duveneck said. The metal halide lighting had to be replaced every two to three years, and gaining access to some of the plant lights was very difficult. Reaching the lighting located over large production equipment required renting lift equipment and personnel time. “The lift rental and labor cost is more expensive than the bulb. “So despite [being motivated by] the electricity savings we get from the lights, the main motivation for this ret- rofit was the maintenance savings,” Du- veneck said. “Now we don’t have to touch the lights again for 10, 15 years.”
Bright Results, Bright Future
Altogether, the company has installed
nearly 650 high-bay LED lighting fixtures in the warehouse and plant—
almost all of the plant lighting. It is one
of the largest LED installations of its
kind, according to the lighting manufacturer’s spokesperson.
Initially there was some resistance
from employees who worried about
glare and because the LEDs are a lot
brighter than the metal halides. “It took
us some time to adapt to them, but
now, when you walk through the plant
and you see the old yellow ones, it’s
clear that these are crisp white and
more useful light than the metal halides,” Duveneck said.
Although the LEDs are substantially
whiter and brighter than the metal ha-
lides, the company exchanged the met-
al halides with LEDs on a one-for-one
basis. “We wanted to make sure we
actually improved the lighting while still
reducing our energy,” he said.
Editor Kate Bachman can be reached at
kateb@greenmanufacturer.net.
Photography by Andrew Shurtoff for Green
Manufacturer, except where other wise noted.
WhiteWave Foods, 6364 S. Valley Pike,
Mount Crawford, VA 22841, 540-434-7328,
www.whitewave.com
Rebate a Tasty Treat
Enhancing the cost savings, Dominion
Power, the company’s utility provider,
offers a number of rebates to its customers for various lighting types. White-
