Cost-Savings And Improved Performance Through LED Lighting Implementation

Glen Raven Logistics selected both lighting and layout as areas of improvement for the company's new found space in 2007. The Glen Raven team worked with Cree to update the current lighting system with a smart LED system.

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This article originally appeared in the March edition of IMPO Magazine. To view the digital version, click here

Glen Raven Logistics is located in Altamahaw, NC on the same property where Glen Raven, Inc. was originally founded in 1880. While the facility itself was previously a manufacturing facility, it was retrofitted in 2007 for Glen Raven Logistics. Dan Cox, president of Glen Raven Logistics, envisioned a full-service logistical partnership for his customers utilizing the new found space. Both lighting and layout were selected as areas for improvement, specifically to address the 400 watt metal halide HID fixtures that were positioned to illuminate the large machinery that once occupied the center of the facility floor. The Glen Raven team turned to lighting solutions provider Cree to update the existing lighting with smart LED lighting for improved performance and energy savings.

Previously, the warehouse lights stayed on most of the day, even when there wasn’t any activity in the warehouse or freight docks. “We were spending a lot of money on virtually wasted energy for lighting when there wasn’t any activity in the warehouse,” stated Cox. “We really needed a lighting system that was smart enough to know when to come on fully when needed and either dim down or turn off when there wasn’t activity in the warehouse.” To meet this requirement, Glen Raven Logistics chose Cree LED lighting that had embedded “smarts” to know when the lights needed to come on with sensors and when to dim down and shut off after a specified period of time with no activity. The relighting of the warehouse centered on using the intelligent lighting to light the space more efficiently and effectively.

In addition to improving the lighting levels and uniformity, the new lighting reduced the total number of fixtures from 274 to 122, which represents a reduction in the total number of fixtures by 56 percent. The high bay fixtures, incorporating zero re-strike time, allow the integrated motion sensors to quickly turn on with any movement in the warehouse and turn off with an adjustable timing sensor that can be adjusted by personal and operational preference. In the Glen Raven facility, the off time is set at four minutes after sensing no motion in the warehouse. This feature is assisting in delivering a large impact on the energy savings.

In the warehouse loading dock area with lower ceilings, not as much light was required as in the high bay areas of the warehouse. Canopy lighting, with programmed motion sensors and dimming, provides just the right amount of light. The flat lenses in the fixtures eliminated any problems with glare that had been an issue with the lower areas of the warehouse. The LED fixtures drop to 20 percent energy while dimmed and turn off totally when no motion is sensed.

“Through the entire project, the Cree LED lighting has proven to be a great fit for Glen Raven and has exceeded our expectations. We are watching our monthly energy costs in anticipation of surpassing our anticipated savings. The entire organization is excited to receive the almost immediate financial impact on the energy conservation in our warehouse. Not only did we cut the number of high energy fixtures by 50 percent, but we are now able to use the lights only during occupancy, greatly reducing the amount of time that we are burning energy. This goes along perfectly with our corporate sustainability values, as we are landfill free in all of our U.S. facilities,” states Mike Harrington, Glen Raven project manager. “I am extremely proud of Glen Raven for making the investment in this LED lighting project. It is proof that we, as a company, are taking the necessary steps to create the safest and most environmentally sustainable work place in our industry. Additionally, it confirms to our associates our willingness to continue to invest in the long-term vision and success of Glen Raven,” commented Steven Losiewicz, vice president of operations.

To further increase the benefits of choosing Cree LED lighting, Cree assisted in identifying and obtaining utility incentives for the project that also contribute to reaching a positive payback in less than two years.

Intelliegent lighting solutions improved performance and big energy savings to Glen Raven Logistics, a company with an innovative focus on the future.

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