LED Lighting Upgrade Case Study Flex-N-Gate Stamping

LED Network Lighting Case Study

Flex-N-Gate Stamping

HOW THE SAFETY SOURCE SAVED FLEX-N-GATE STAMPING OVER $22,000 ANNUALLY ON THEIR ELECTRICITY BILL. WITH AN ROI UNDER 1 YEAR!

Why Should You Upgrade To LED Lighting?

75%-90% energy savings over incandescent, halogen, HID and fluorescent fixtures.

ZERO MONEY DOWN!! That's right we can upgrade your lighting to LED and you don't have to spend $1. Ask us how we can help you upgrade without spending $1.

LED bulbs consume 80% less energy when compared to incandescent light bulbs.

Maintenance Cost Avoidance (MCA) is minimum 5 years and can be as long at 15 years with our Best In Class LED fixtures having 200,000 hours life expectancy and a 10 year warranty.

Tax Deductions are available for upgrading to LED fixtures, the

EPAct 179D may allow your business a significant tax deduction.

LED fixtures contain no harmful mercury and use less energy and produce higher light output.

Comparison of warehouse lighting before and after improvements.

Overview

The Safety Source LLC partnered with Flex-N-Gate Stamping to implement a strategic LED lighting upgrade at their production facility located in Warren, Michigan. The facility relied on legacy high-bay fluorescent lighting with no occupancy controls, resulting in excessive energy consumption, high operating costs, and inefficient lighting performance.

The goal of this project was to modernize the lighting system using high-efficiency LED fixtures and intelligent occupancy controls, delivering immediate energy savings, improved lighting quality, and a fast financial return.

Project Objectives

Reduce Energy Consumption: Significantly cut down on energy usage through the installation of efficient LED lighting. Implement network lighting and occupancy sensors.
Improve Lighting Quality: Enhance the overall lighting quality within Flex-N-Gate's facilities.
Environmental Impact: Lower the carbon footprint by reducing energy consumption.

Results

Overall Energy Savings: The project achieved a 67% reduction in energy use across various lighting applications, with occupancy sensors helping to minimize energy consumption in low-traffic areas.
Improved Lighting Quality: Switching to LED fixtures significantly improved lighting quality, enhancing visibility and comfort, and more than doubling light quality in some areas.
Cost Savings: The energy savings translated into over $23,000 in annual energy cost savings for Flex-N-Gate Stamping. Additionally, annual maintenance costs were reduced by $6,000 leading to total savings of $730,000 over twenty years.
Environmental Impact: The project contributed to a notable reduction in Flex-N-Gate's carbon footprint.

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Scope Of Work

Reduced high bay lighting energy consumption by 67% by replacing 132 288W T8 fluorescent fixtures with 132 100W Litetronics High Bay Pro LED Fixtures.

Reduced high bay lighting energy consumption by 67% by replacing 72 234W T8 fluorescent fixtures with 72 70W Litetronics High Bay Pro LED Fixtures.

Added 204 Litetronics SC008 Plug In Bluetooth PIR Sensor to every new highbay. Reducing energy consumption even more and giving more lighting control to the end-user.

Environmental Impact

67% carbon reduction

Equivalent number of cars removed from road 34

Equivalent number of trees planted 2,699

Savings & Rebate

Annual Electricity Savings $22,853.37

Reduced maintenance costs by $5,803.20 annually, no need to replace lamps or ballasts for minimum of 5 years.

Rebate amount captured from DTE Energy $32,271.36

Payback/ROI

11 Month ROI, 10 year warranty on fixtures.

- Step 1 -

Lighting Analysis

The Safety Source will perform a free comprehensive lighting analysis of your interior and exterior lighting.

- Step 2 -

Rebate Calculation

We analyze your current lighting scheme with the help of our program calculator to estimate any rebates you will receive for updating to LED.

- Step 3 -

Cost Reduction

After we determine the cost of upgrading your lights to LED, our software calculates the reduction in your monthly electric bill you should expect.

- Step 4 -

Installation

We install your new LED lights! After our turnkey installation, your energy bill will drop immediately and you will begin to see the savings on your next (and every subsequent) energy bill. Typical ROI is under 2 years.

The Safety Source has retrofit over 70 million sq. ft. of industrial and commercial space throughout the United States and Canada since 2008. We have performed these projects for the worlds largest OEM and Tier I automotive manufacturers, multiple car dealerships, distribution centers, retail stores, churches, schools, and hospitals.