Use of LED Technology within a PRW

Michael Lynch Vice President of Engineering

Good Lighting: Key to Optimum

Warehouse Performance
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.

Warehouse Lighting Requirements

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

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%

Mercury
content (mg)

~15 mg

~81 mg

~5mg

0mg

Cost/Fixture

$250 - $325

$300 - $375

$350 - $450

$650 - $750

Benefits of LED Technology

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

Lighting Heat Load Calculations

ASHRAE defines the instantaneous rate of heat
gain from electric lighting as follows:
Q = 3.14 x (W) x (FUT) x FSA x CLF
Where:
Q = Instantaneous rate of heat gain; btu/hr
W = Input Watts
FUT = Lighting Use Factor
FSA= Special Ballast Allowance Factor
CLF = Cooling Load Factor

160 watt High Bay LED

Case Study #1: Hazleton, PA

Our companies first LED installation
Commissioned October 2010
Daily Cost Summary = Electricity + Refrigeration
24/7/365 day operation
23% aisle occupancy (assumed)
Lighting Option

Daily Cost ($)

(107) 350 watt Metal Halide (bi-level @ 50%)

$65.33/day

25%
room
occupancy
(average)
(107) 221watt
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

Case Study #1: Hazleton, PA (cont.)

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.)

Case Study #1: Hazleton, PA (cont.)

Case Study #2: Fort Worth, TX

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%

LED Lessons Learned (so far)

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 Photopic
perception 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.

References
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

Thank You