The Rogers plant recently completed a lighting retrofit project which will result in better lighting and reduced energy usage.
Before
After
We replaced old high bay metal halide and obsolete T-12 fluorescent fixtures with energy saving high efficiency T-8 fixtures in our wet wire drawing department. The metal halide high bay fixtures were replaced with 6 lamp four foot T-8 fluorescents that included motion sensors that turn the fixture off after a preset time out.
Clarification
We replaced the metal halide high bays in the warehouse with the same 6 bulb fluorescents but were able to use a dual technology sensor in this area that includes daylight harvest sensing along with motion detection. This sensor will turn on the fixture if motion is detected but only if it is not already light enough to work safely. The building has skylights and this allows us to maximize our savings. OSHA does not allow us to use this technology around rotating equipment.
Environmental Savings
Projected annual electrical savings of $51365 gives a four year payback in simple terms with an estimated energy cost of $0.052 per KWH. This also addresses the issue of replacing obsolete light fixtures for which replacement parts and bulbs will become an issue. The majority of these fixtures are due or past due for re-lamping which will result in a cost avoidance.
This project is also environmentally friendly in that it is projected to reduce our CO2, methane and nitrous oxide emissions. The new T-8 lights have a longer lamp life with less lumen loss over the life of the lamps. This will reduce maintenance cost and should improve housekeeping and productivity.
Due to the energy savings of this project the state of Arkansas has awarded the plant a $100,000 grant to help offset the cost of the project. The project took approximately 6 weeks to complete and was done while the plant continued to operate at full production.
Project Partially Funded by the America Recovery & Reinvestment Act
