Installation of Digital Lumens LED-based Intelligent Lighting System throughout 42 735 m2 facility slashes company’s carbon footprint and increases light levels by 53%

With annual revenues approaching € 2.22 billion, Maines Paper and Food Service, Inc. is one of the United States' largest broadline food distributors. Through its network of warehouse facilities, the company serves customers in 35 states, offering competitively priced, quality food service products backed by exceptional levels of service. Operationally, Maines leads the industry in its commitment to sustainability and setting new standards in workplace productivity and safety.

It is this commitment to excellence that led Maines to re-evaluate the lighting needs at its 42 735 m2 headquarters facility in Conklin, NY. Like any large warehouse with 24 x 7 operations, the spotlessly clean Conklin facility bustles with activity across all shifts. To rapidly pick and replenish product, forklift operators regularly zip back and forth through both ambient space and cold storage environments, which range from 22°C dry storage areas to 4°C refrigerated spaces to -28°C ice cream freezers. They rely on proper lighting to ensure safety and performance.

Until recently, the facility was illuminated with hundreds of 400W high-intensity discharge (HID) fixtures — a decade-old solution that resulted in under-lit spaces and poor-quality light. The challenge for the management team was finding a more energy efficient and sustainable solution that produced — and subsequently maintained — higher levels of quality light, a key driver of safety and productivity.

Case StudyMaines Paper and Food Service, Inc. Reduces Lighting-Related

Energy Use by 87% in Showcase Facility

Maine’s Paper and Food Service, Inc.

OPERATIONAL SCHEDULE24 x 7

ENVIRONMENTAmbient, cold, and refrigerated spaces

TEMPERATURE RANGE-28° to 22°C

PREVIOUS LIGHTING SOLUTION400W High Pressure Sodium (HPS)

UTILITY PARTNERNYSSERDA

Figure 1: Before and AfterThe images above show the original 400W high-pressure sodium fixtures (left), which give off a signature yellowish light. On the right, the Digital Lumens Intelligent Lighting System provides high-intensity illumination when and where needed, using only 160W when fully illuminated.

“Our experience with Digital Lumens put to rest any questions we had regarding the use of LED-based light fixtures in complex warehouse environments.With the Intelligent Lighting System, we now have access to a long-lifecycle, low maintenance, high-quality lighting source that provides the in-depth usage data we require to fine-tune our system to meet actual, versus estimated, needs. The result is a smarter, vastly more efficient and sustainable solution that puts us firmly in control of our lighting, today and in the future.”

Pat DeOrdio, VP of Operations, Maines Paper and Food Service, Inc.

Conklin, NY — 42 735 m2 facility

Maines Paper and Food Service, Inc.EVALUATING THE OPTIONSThe facilities team considered fluorescent fixtures as a possible solution in both cold and dry spaces. However, to achieve desired light levels, they would need to install 8-lamp high-intensity fluorescents (HIF) at 300W each, which quickly eroded the potential energy savings and, as a mercury-based light source, created hazardous waste issues and costs. There were also significant concerns surrounding fluorescent fixture performance in a cold environment. The search continued.

THE RIGHT SOLUTION FOR DEMANDING INDUSTRIAL APPLICATIONSThe management team, working with their energy efficiency partner, then evaluated a new class of highly efficient LED-based lighting solution from Digital Lumens, the Intelligent Lighting System. Designed specifically for demanding industrial applications, the Intelligent Lighting System integrates high-intensity LEDs, sensing, networking and software-based intelligence into a single system that maximizes light delivery and minimizes energy use.

Following a pilot installation, which included carefully evaluating the system in both dry and cold environments, the Maines team decided to retrofit its 400W HID fixtures with the Digital Lumens solution. Installed as one-for-one replacements for existing high bay fixtures, the Intelligent Lighting System:

• Performed exceptionally well in all of the facility’s environments;

• Required little or no maintenance or re-lamping;

• Produced instant, high-quality light when, and where needed; and,

• Provided the Maines team with the data they required to document energy use and continuously improve performance over time.

Maines’ installation of the Digital Lumens Intelligence Lighting System qualified for financial incentives from the New York State Energy Research and Development Authority (NYSERDA), an organization that helps businesses across the state enhance operational efficiency by funding sustainable, energy-efficient projects. NYSERDA’s focus on reducing energy consumption and protecting the environment dovetailed nicely with Maines’ strategic goals.

A BRIGHT FUTURE FOR ENERGY SAVINGSWith a payback of less than two years, driven by massive energy savings, the Digital Lumens solution has proven to be a perfect fit for Maines. Since deployment, the Intelligent Lighting System has dramatically increased light levels for facility staff, while driving down energy usage by a documented 87%. Maines expects to save 1 726 108 kWh and eliminate 1 240 metric tons of carbon dioxide (CO2) per year — equivalent to removing 200 homes per year from the grid. Those results contribute significantly to the safe and sustainable work environment at Maines.

Case Study

Figure 4: Digital Lumens’ Intelligent Lighting System uses 89,3% fewer kWh than alternatives. Data gathered at 15-minute intervals from a 400W HID fixture, a 300W fluorescent alternative, and the Digital Lumens system shows cumulative energy use in a 24-hour period. The Digital Lumens fixture enters a true ‘standby’ mode — and consumes zero power — whenever an aisle or work area is vacant and uses only 1,2 kWh/day. The HID fixture must remain ON to ensure immediate light delivery (11,96 kWh/day). The fluorescent consumes 6,98 kWh/day in standby mode.

Figure 2: The Maines team that evaluated and selected the Digital Lumens solution. From the left, James McColloch, Director of the Warehouse; Eddy Osorio, Facility Manager; and Pat DeOrdio, Vice President of Operations.

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Ave

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Time of Day

Average Power Consumption

HID

HIF

DL

400W HPS 11.16 kWh / day

8-lamp T8 (dual ballast) 6.98 kWh / day

Digital Lumens ILE-HB-3 1.20 kWh / day

15 minute intervals

Figure 3: Light Meter Reading. The Intelligent Lighting System achieves 215 lux of illumination at the aisle task level.

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