LED’ing the way–Energy Savings and Cost Avoidance

“LED” has become an ever-present term in the world of industrial lighting read more on LED lighting. LEDs offer two very important advantages over older lighting systems:

  • Extremely long system life (case study: 100,000 hours)
  • Reduced energy usage (case study: consumes 1/3 of the existing wattage)

We’ll circle back to cover what that means to your bottom line $$$ later in the post.

Comfort levels with LED lighting systems have been increasing. Ten years ago, it was a relatively new technology. Perhaps only progressive and open-minded facilities and finance professionals were looking in that direction. Today, in 2016, the products are available from proven sources and at a cost point that makes LED an option for most industrial plants.

Let’s look at three (3) great examples of easy, efficient and effective LED lighting upgrades. All three of these examples come from one case study project. This case study focuses on a large automotive manufacturing plant located in Western New York. All of the examples included below dealt with outdoor lighting – inclusive of parking lot, rooftop lighting and more.

  1. Example 1: parking lot poles, 1000W metal halide, “shoe box”
  2. Example 2: wall pack fixture, 400W mercury vapor lamp
  3. Example 3: incandescent 100W lamp, “jelly jar” fixture

So why was this project such a success for the end user? All substitutions made replaced lamps that were nearing the end of their useful life and were updated with lamps rated for 100,000 hours of useful life. Most will ask… “what does that mean?” and then they’ll pull out their phone and pull up the calculator tool.

To save you that step, let’s walk through the math: If an LED lamp lasts 100,000 hours, and is on for 8 hours a day, that lamp will last about 12,500 days. In 2016 (a leap year, mind you) there are 251 working days. That LED lamp will last 49.8 years, if you round up – approximately 50 years.

Alternately, if a lamp is on 24 hours a day, 7 days a week, that LED lamp would last approximately 4,166 days. Assuming the lamp is on 365 days, that LED lamp will last about 11.4 years.

Here’s a review of the three examples given above:

  1. Example 1: parking lot poles, 1000W metal halide, “shoe box” Replaced with this
    On for 4,380 hours per year = this new system should last 22.8 years
  2. Example 2: wall pack fixture, 400W mercury vapor lamp Replaced with this
    On for 4,380 hours per year = this new system should last 22.8 years
  3. Example 3: incandescent 100W lamp, “jelly jar” fixture Replaced with this
    On for 4,380 hours per year = this new system should last 22.8 years

Why is long lamp life important? First, you won’t need to purchase new lamps. If you don’t have to purchase new exterior lighting for the next 50 years, that’s a good thing. It is also important because a sizable cost of upgrading or replacing lighting is the labor to change out the lighting fixtures and/or lamps. Getting a maintenance worker on a ladder or scaffold takes time and money. Long lamp life drives cost out of your facilities and maintenance budget.

This project has been a success for the end user because of the reduced energy usage. All of the substitutions that they made replaced high wattage lamps with lower wattage. Again, here’s a review of the three examples given above:

  1. Example 1: parking lot poles, 1000W metal halide, “shoe box”
    Going from 1000W to 282W per fixture, 58 fixtures = $8,000 to $20,000 *PS1
  2. Example 2: wall pack fixture, 400W mercury vapor lamp – Assuming a $0.10 KWH rate
    Going from 400W to 105W per fixture, 37 fixtures = $5,700 *PS2
  3. Example 3: incandescent 100W lamp, “jelly jar” fixture – Assuming a $0.10 KWH rate
    Going from 100W to 20W per fixture, 24 fixtures = $840 *PS3

Typically, a KWH sells for $0.10 in the Northeast United States. For the entire project, this represents an annual energy savings of $64,756. That could mean a lot of things to your company – a new hire, new equipment, and so on.

  • If you want to save energy because it’s good for the environment
  • If you want to save energy because it’s good for business
  • If you are looking for a way to avoid and drive down costs

If you have lighting questions feel free to reach out to one of our Lighting Specialists.

What challenges does your team face when looking at a lighting upgrade? Share your story in the comments.

Postscripts

*PS1: Energy Savings Example #1
1000W non-LED fixture, actually draws 1080W. Going down to 282W, 798W savings per fixture.
798W x 4380 hours of run life / 1000 KWH = 3495 KHW per fixture, per year.
If your energy were to cost $0.04/KWH, with 58 fixtures you would save $8,108 per year.
If your energy were to cost $0.10/KWH, with 58 fixtures you would save $20,271 per year.
Further examples will use $0.10 KWH rate.

*PS2: Energy Savings Example #2
400W non-LED fixture, actually draws 459W. Going down to 105W, 354W savings per fixture.
354W x 4380 hours of run life / 1000 KWH = 350.4 KHW per fixture, per year.
Energy cost $0.10/KWH, with 37 fixtures you would save $5,736.92

*PS3: Energy Savings Example #3
100W non-LED fixture. Going down to 20W, 80W savings per fixture.
80W x 4380 hours of run life / 1000 KWH = 1550.5 KHW per fixture, per year.
Energy cost $0.10/KWH, with 24 fixtures you would save $840.96

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