use led technology
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tecnologia ledTRANSCRIPT
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Use of LED Technology within a PRW
Michael Lynch Vice President of Engineering
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Most warehouse facilities have a variety of functions performed beyond just pallet storage:
Picking operations Packaging Maintenance inventory control
Good lighting is essential in a warehouse to promote worker safety, performance and morale.
Good Lighting: Key to Optimum Warehouse Performance
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Per OSHA 29 CFR, 5 foot-candles is the minimum lighting level required for general construction areas, warehouses, corridors, hallways and exit ways.
Industry best practice recommends 10-20 foot-candles for active warehouse aisles.
Some factors affecting aisle light levels: Lumen depreciation Lens clarity Aisle occupancy
Warehouse Lighting Requirements
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Current Lighting Technologies
High Pressure Sodium
Pulse Start Metal Halide
Fluorescent T5/T8
LED
Legacy < 2000 1995 - present 2003- present > 2010
Input Watts (w) 465 watts 458 watts 342 watts 160 watts
CRI 22 65 80 78
Efficacy (l/w) 97 51 78 62
Lamp Life (hrs) 23,000 18,000 25,000 90,000+
Lumen Depreciation
20%-25% 25%-30% 8% - 10% 8% - 10%
Mercurycontent (mg)
~15 mg ~81 mg ~5mg 0mg
Cost/Fixture $250 - $325 $300 - $375 $350 - $450 $650 - $750
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Less input watts required compared to alternatives Less heat load in freezer compared to alternatives Superior Dimming Capability
Dim down to zero percent (off)
Instant on capability From off to full on instantly
Long useful life in freezer environment 90,000+ hours Less re-lamping and recycling costs
Five year warranty
Benefits of LED Technology
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ASHRAE defines the instantaneous rate of heat gain from electric lighting as follows:
Q = 3.14 x (W) x (FUT) x FSA x CLFWhere:
Q = Instantaneous rate of heat gain; btu/hr
W = Input Watts
FUT = Lighting Use Factor
FSA= Special Ballast Allowance Factor
CLF = Cooling Load Factor
Lighting Heat Load Calculations
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160 watt High Bay LED
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Our companies first LED installation Commissioned October 2010 Daily Cost Summary = Electricity + Refrigeration
24/7/365 day operation 23% aisle occupancy (assumed)
25% room occupancy (average)
Case Study #1: Hazleton, PA
Lighting Option Daily Cost ($)
(107) 350 watt Metal Halide (bi-level @ 50%) $65.33/day
(107) 221 watt 6-lamp T8 (bi-level @ 50%) $49.92/day
(107) 160 watt LED (off after 1 minute) $13.72/day
(107) 160 watt LED (off after 30 seconds) $10.02/day
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Zigbee wireless network Programmable settings for light output, sensor delay and
inactive state
Data reporting, analysis and energy management Optimize time and occupant programming
Case Study #1: Hazleton, PA (cont.)
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Case Study #1: Hazleton, PA (cont.)
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Case Study #1: Hazleton, PA (cont.)
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Our companies first LED Retrofit Commissioned December 2010 Replaced (133) 400 watt HPS and (234) 400 watt
MH fixture with (360) 160 watt LEDs
Capital Justification based upon: $432,500 capital cost $131,100 annual savings (energy + refrigeration) $44,750 rebate from pubic utility (Oncor) Internal Rate of Return (IRR) = 25.1%
Case Study #2: Fort Worth, TX
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LED instant on capability functional down to -22 F. Forklift operators perception is that aisles are brighter
when in fact they are not. Scotopic verse Photopicperception of light.
Operator apprehension when entering a dark freezer. LEDs may interfere with some freezer door motion
sensors. Adjustment may be necessary.
Upper pallet faces not illuminated as well as previous HID fixture.
LED Lessons Learned (so far)
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United States Department of Labor, Occupational Safety & Health Administration; Standard 29 CFR; 1926.56(a)
Complete Guide to Modern Warehouse Management; Jenkins; 1990
ASHRAE Fundamentals Handbook; 2009 Illuminating Engineering Society (IES) WideLite; Philips Electronics N.V. Lithonia Lighting; Acuity Brands Company Digital Lumens AlbeoTechnologies
References
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Thank You
Use of LED Technology within a PRWGood Lighting: Key to Optimum Warehouse PerformanceWarehouse Lighting RequirementsCurrent Lighting TechnologiesBenefits of LED TechnologyLighting Heat Load Calculations160 watt High Bay LEDCase Study #1: Hazleton, PACase Study #1: Hazleton, PA (cont.)Case Study #1: Hazleton, PA (cont.)Case Study #1: Hazleton, PA (cont.)Case Study #1: Hazleton, PA (cont.)Case Study #2: Fort Worth, TXLED Lessons Learned (so far)ReferencesThank You