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U.S. Department of Energy data indicates that, on average, 30 percent of all energy consumed in commercial buildings is used for . Installing more efficient technologies and products is a cost-effective strategy for industry, and represents an eco-friendly cause that OSRAM SYLVANIA has championed for more than 25 years. In keeping with the corporate mission to reduce energy consumption at OSRAM SYLVANIA facilities by 10 percent this fiscal year, SYLVANIA Lighting Services recently completed retrofit projects at both the Eastern Distribution Center in Bethlehem, Pa., and the Midwest Distribution Center in Versailles, KY.
Both retrofit projects involved a complete conversion from HID to fluorescent systems that use motion sensors. For the Eastern Distribution Center, this constitutes the second retrofit since it came online in March 1997. “Sustainability and energy conservation always have been key components for the distribution centers,” confirms Peter van Breda, director of warehousing and distribution.
THE LATEST RETROFIT
The Pennsylvania facility’s first retrofit in 2000 involved the removal of 1,000-watt HID lamps, replaced by new fixtures fitted with 400-watt HID controlled by motion sensors. The most recent re-lamping installed new T5 fixtures with state-of-the-art, motion-sensor technology. In Pennsylvania, six-lamp and 10-lamp T5 fixtures were deployed to replace existing HID fixtures. The project required four weeks to complete.
The Midwest Distribution Center opened in March 2004. Original featured a smattering of T5 fixtures with the remaining majority comprised of 400-watt HID. This year’s retrofit replaced all HID fixtures with T5 fixtures operating with motion sensors. Motion sensors represent a complementary driver in both projects to further improve energy savings. After all, every aisle of both 500,000-square-foot facilities is not typically occupied by employees around-the-clock. “The key in all of this was to reduce our energy consumption while, at the same time, improving quality – which we defined as both better and more even distribution,” explains van Breda. “The next step in our energy-saving efforts will be to install large ceiling fans up to 20 feet in diameter to rotate interior air, which should significantly reduce the use of natural gas for our distribution centers.”
By comparison to most consumption-reduction strategies, re offers a quick and dramatic return on investment. According to Frank Ciampa, the account representative for the Pennsylvania facility, the Eastern Distribution Center retrofit will pay for itself in two and a half years. “This project shows that fluorescent T5 technology is a great way for customers to get immediate savings,” says Ciampa. “And because the fluorescent fixtures allow for motion sensors, the savings are likely to be greater than projected, especially considering the volatility of energy prices.”
MORE LIGHTING UPGRADES
These ambitious projects necessitated widespread cross-disciplinary cooperation. Midwest Distribution Center Operations Manager Robert Sparks and SYLVANIA Lighting Services Project Supervisor Sam Kelley were vital individual catalysts. Sparks was a key factor in the design, approval and logistics of the Kentucky facility project. Kelley liaised with Sparks and Midwest Distribution Center Executive Account Representative Mike Payne to ensure timetables and specifications were met. Lighting upgrades also have been completed at the St. Marys and York, Pa., plants. The projects will pay for themselves – in energy savings and federal energy-conservation tax credits – in about 18 months. Similar retrofit proposals at four other plants are either on the drawing board or awaiting approval.
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