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MEEA Industrial Webinar: Industrial Load Reduction: The Role of Intelligent LEDs in an Energy Efficiency Portfolio
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MEEA Industrial Webinar: Industrial Load Reduction: The Role of Intelligent LEDs in an Energy Efficiency Portfolio


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C&I customers represent a substantial opportunity for load reduction, but the key is to incentivize projects with excellent performance, economics, and impact. Intelligent LED systems are redefining …

C&I customers represent a substantial opportunity for load reduction, but the key is to incentivize projects with excellent performance, economics, and impact. Intelligent LED systems are redefining the lighting category and displacing legacy technologies with proven results.

The webinar, presented by Michael Feinstein from Digital Lumens, will cover the following topics:
• Industrial lighting technology review
• Intelligent LED System overview
• 90% energy reduction – the economics of intelligent LEDs
• Large C&I lighting customers – retrofit & new construction case studies
• Future of intelligent LED lighting

Mike Feinstein is responsible for leading the Digital Lumens sales and marketing teams and has had extensive experience in the entrepreneurial and investment worlds, most recently as Managing Director of Sempre Management. Previously, he was a General Partner at Venrock Associates and Atlas Venture, where he served on the boards of start-ups including Boston-Power, Ciclon Semiconductor (acquired by Texas Instruments), CircleLending, WaveSmith Networks (acquired by CIENA Corp.) and Quantum Bridge Communications (acquired by Motorola). Michael holds a B.S. in Electrical Engineering and Computer Science from MIT.

This presentation is part of the Midwest Energy Efficiency Alliance Industrial Webinar Series. Find out more at

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  • 1. MEEA’s Midwest Industrial InitiativeWebinar:Industrial Load Reduction: TheRole of Intelligent LEDs in anEnergy Efficiency PortfolioFebruary 28, 201311:00AM-12:00PM CST
  • 2. MEEA’s Role in the Midwest• Non-profit serving 13 Midwest states• 10+ years serving state energy offices, utilities,ESCOs, state and local government, manufacturers• 150+ Members• Staff of 25 in Chicago• Actions– Advancing Energy Efficiency Policy– Promoting Best Practices– Delivering Training & Workshops– Coordinating Multi-Utility Program Efforts– Designing & Administering Energy Efficiency Programs– Evaluating & Promoting Emerging Technologies– Regional Voice for DOE/EPA & ENERGY STAR
  • 3. Midwest Industrial Initiative (MI2)In Fall 2010, MEEA has created the MI2 in order to:• Promote adoption of energy efficiency in the industrial sector• Provide information on electric and natural gas utility energyefficiency rebates and programs• List national and local energy efficiency best practices andtechnology information• Offer catalog of case studies of successful energy
  • 4.• Dedicated website on Industrial Efficiencyin the Midwest– Utility, state and local case studies– Catalogue of utility industrial contacts– Utility programs– Industrial opt out and self direct policies– EIA data by state and fuel• Social media presence–
  • 5. MI2 Activities• Quarterly regional utility calls• Midwest presence for SEEAction Industrial workinggroup and CHP group• Developing Midwest CHP working group• MI2 to be conduit of efficiency information toindustrial companies and industrial associations• Promote successful efficiency programs,technologies and financing mechanisms
  • 6. MI2 Upcoming Webinars• Mitsubishi – review of manufacturingfacility improvements• Baltimore Gas & Electric – CHP as part ofcost effective efficiency program• Schneider Electric – Energy reductionefforts• Dates Forthcoming…
  • 7. Reminders for Today’s Webinar• Submit questions in the chat box in theright panel• Q&A will take place after the presentationis complete• Presentation will be available on
  • 8. MEEA Staff Contacts• Jay Wrobel, Executive• Stacey Paradis, Deputy• Chelsea Lamar, Senior Program• Rick Holmes, Senior Advisor, Industrial Initiatives,
  • 9. Industrial Load ReductionThe Role of Intelligent LEDs in an Energy Efficiency ProgramMidwest Energy Efficiency Alliance | Midwest Industrial Initiative© 2013 Digital Lumens
  • 10. Agenda• Industrial lighting technology review• Intelligent LED System overview• 90% energy reduction – the economics of intelligent LEDs• Large C&I customers• Retrofit & new construction case studies• Future of intelligent LED lighting10
  • 11. Legacy Industrial Lighting11HID (MH & HPS)• Highest operating cost• Significant heat output increases HVAC load• 2-year relamping• Contains mercury and lead – difficult/costly disposal• No ON/OFF cycling capabilityFluorescent T12• Does not fully illuminate when first turned on• Re-lamping/reballasting• Minimal ON/OFF cycling• Contains mercury – difficult/costly disposal
  • 12. Current Industrial Lighting12Fluorescent T8 & T5HO• More efficient than T12 predecessor, however many issuesremain:• Poor initial illumination, re-lamping/reballasting, minimalON/OFF cycling, contains mercury – difficult/costly disposal• T5HO poor performance in cold temperaturesPlain LEDs• More efficient than fluorescent alternativesIntelligent LED System• Most efficient• Includes fully integrated features that maximize efficiency
  • 13. Legacy Fixtures Current OptionsHID T12 6LT8 6LT5HOLEDsw/sensorsIntelligentLEDsWattage 450 250 300 350 155 155Annualenergy cost$39,420 $21,900 $26,280 $30,660 $6,789 $2,716Annualmaintenance$10,000 $6,500 $6,000 $6,000 $0 $0Upfrontproject costN/A N/A $$ $$$ $$$$ $$$$10 yr energyconsumption(kWh)394,200 219,000 262,800 306,600 67,890 27,15610 yr TCO $494,200 $284,000 $336,800 $380,600 $137,890 $106,656Table assumptions• $0.10/kWh• 100 fixtures• 8,760 hours/year operationEnergy Consumption Comparison• Includes wattage for ballasts for HID, T12, T8 & T5• 10 year TCO figures for Retrofit Options include upfront project costs• 10 year TCO figures for Current Fixtures HID & T12 do not include upfront project costs
  • 14. • Strong LED lighting, networking, and software experience• Award-winning company and technology• Integrates LED-based luminaires with built-in controls & intelligence• Reduces lighting energy use by up to 90%• Optimized for rugged industrial environments• Lowest total cost of ownership (TCO)14Leading the Way in Intelligent Lighting
  • 15. Intelligent Lighting Drives Maximum Savings15Networked Together Centrally ManagedSmart LightsThe Complete Solution
  • 16. 100% of the light for 10% of the energy• Reduced wattage• Fully integrated:• Sensing• Dimming• Daylight harvesting• Local intelligence• Central control• Great light quality16
  • 17. 17Intelligent fixtures to address each facility’s uniqueneedsILE-3-18• 18,000 lumens• 215W• 26,000 lumens• 325WILE-3-26• Up to 50’ mounting height• Three independently rotatable LEDlight bars• Integrated occupancy sensors• Integrated daylight harvesting• Wide or narrow optics options• Onboard intelligence to manage fixturebehavior• Wirelessly connected to LightRulesTMmanagement software• 107,000 hour lifetime rating• 5 year warrantyALLFIXTURESFEATURE:ILE-3-13• 13,000 lumens• 155W
  • 18. 18• Occupancy sensors designedand manufactured by DigitalLumens• Fully integrated into each fixture• Each sensing package featuresthree infrared sensors• Higher ceiling heights• Improved performance• Dimming, also integrated intoeach fixture, can beprogrammed from 0-100%High Performance Occupancy Sensing & DimmingFacility occupancy map
  • 19. Average Industrial Occupancy RatesData pulled from 40 Digital Lumens customer sites:• Cold storage 15%• Dock 40%• Dry storage 30%• Manufacturing 35%19
  • 20. 20Effect of Occupancy Sensor Settings on EnergyConsumptionOccupancy Sensor Log Data4:30pm 5:30pmSensorDelay% “Active” ILE EnergyCost*(155W)HIF Energy Cost*@ 15 mins (220W)30 sec 25.2 % $35 / yr $19060 sec 40.8 % $57 $19090 sec 52.4 % $73 $1903 min 72.5 % $102 $1905 min 89.3 % $125 $19010 min 98.6 % $138 $190* 10¢ /kWhBased on 25% occupancy
  • 21. 21• Automatically assesses available ambient and adjusts light outputaccordingly to illuminate area with target light level• Photo sensors fully integrated into each fixture• Depending on available ambient light, reduces lighting use by anadditional 25-50%• Consistent light quality throughout the spaceDaylight Harvesting
  • 22. • Active levels• Inactive levels• Occupancy sensortimeoutsLightRulesTM Control Software22• Energy consumption• Energy costs• Energy savings• Facility occupancy• Daylight harvesting• What-if analysisControl Report
  • 23. 23Control, Edit & ReportDashboard SchedulingOccupancy MapFacility MapEnergy ReportsProfile Management
  • 24. • Customize lighting profiles by zone,e.g.:• Loading docks• Frozen storage• Ambient storage• Minimize lighting energy costs whilemaximizing operator efficiency & safety• Automated or manual control• Full system flexibility• Interoperability & API• Managed lighting = managed costs24Customized Lighting
  • 25. Intelligent Lighting SystemSavings Summary25IntelligenceLED powerreduction(watts)IncentivesFine-tuningHVAC & chillerload reductionMaintenance
  • 26. 26Tested & Proven• Robust design• Rugged and integrated technology• Tested, certified, listed, and labeled• UL, CE/CB, DOE, Lighting Facts, DLC, NEMA IP Rating, LM79, LM80• Outstanding support• 5-year warranty• Backed by world-class lighting professionals• 107,000-hour lifetime rating
  • 27. DesignLights Consortium27
  • 28. • Deployed in the world’s leading industrial facilities• More than 500 large-scale deployments• Saving customers $25 million and 250 million kWh per year28500+ InstallationsNew Orleans Cold Storage
  • 29. Installation Snapshot: MEEA Region29★★★★★★★★ ★★★★★★★★★★★★★★ ★★★★★★★ ★★★★★★★★★★★★ ★★★★ ★★ ★★★ ★★ ★★★★★★★ ★★ ★★★★★ ★★★★★★★• 85+ installations• 8.5 million+ totalsquare feet
  • 30. In a Variety of Industries and EnvironmentsCustomer Environment Industry StatePepsico Ambient Food manufacturer ILKellogg Cold/freezer Food manufacturer OHMillard Cold/freezer Warehousing/distribution IA, NE, KY, ILConAgra Cold/freezer Food manufacturer MO, IADominos Cold/freezer Food manufacturer & retailer MO, MINestle Cold/freezer Food manufacturer ILSara Lee Cold/freezer Food manufacturer IA, ILUnited Dairy Farmers Cold/freezer Food manufacturer IAReinhart Food Service Ambient Food manufacturer OHInterstate Warehousing Cold/freezer Warehousing/distribution IN, IL, MI, OH
  • 31. MEEA Energy Consumption -– Industrial LightingStateIndustrial EnergyConsumption (M kWh)Lighting EnergyConsumption (M kWh)IA 18,865 5,471IL 44,180 12,812IN 46,552 13,500KS 10,651 3,089KY 45,022 13,056MI 30,841 8,944MN 22,798 6,611MO 17,330 5,026ND 3,850 1,117NE 10,210 2,961OH 53,109 15,402SD 2,360 684WI 10,069 2,920Totals 315,837 91,593
  • 32. MEEA Industrial Lighting Consumption• 91,593 million kWh per year in MEEA territory• Most current lighting fixtures stay on 95% of the time regardlessof:• Occupancy• Ambient light• Opportunity for massive energy savings32
  • 33. Make Lighting Upgrades a Priority33• Lighting accounts for 29% ofindustrial electricity use• Lighting upgrades are a fast & easyway to reduce energy consumption• Have far-reaching energy-savingpotentialSource: U.S. EPA Energy Star Building Upgrade Manual
  • 34. More Energy Savings with Less Work• The average Digital Lumens industrial lightingretrofit = savings of 105,891 kWh• 1,084 residential retrofits, or• 46 commercial retrofits• Do more with less• Focus on key large industrial energy users• Far fewer points of contact and less work for theutility• Quickly achieve energy reduction goals34Source: EPA Fast Facts on Energy Use Canaccord Genuity The Third Cycle version 4.1, Quantifying the Unknown
  • 35. • Facility size: 460,000 ft2• Project type: retrofit• Environment: Ambient, cold, andrefrigerated spaces• Temperature range: -20°F to 70°F• 7 x 24 x 365 operation• Previous lighting solution: Highintensity discharge (HID)• Annual lighting energy savings: 87%• Payback: <1 yearBefore and After9 ft-cd 20 ft-cdCase Study: Maines Paper & Food35
  • 36. 36Case Study: Associated Grocers of New EnglandBefore and After• Facility size: 380,000 ft2 with 56,000ft2 cold storage lighting upgrade• Project type: retrofit• Operational Schedule: 24 x 6• Environment: refrigerator• Temperature: -15°F• Previous lighting solution: T5 HOFluorescent• Annual lighting energy savings:$52,000
  • 37. 37Case Study: New Orleans Cold Storage• Facility size: 142,000 ft2• Project type: new construction• Environment: cold storage• Temperature: -15° to 35°F• Alternative lighting solutionconsidered: T5 fluorescent• Annual lighting energy savings:245,764 kWh
  • 38. 38Case Study: Ben E. Keith• Facility size: 475,000 ft2• Project type: new construction• Environment: cold & ambientstorage• Temperature: to 40°F• Part of major sustainabilityinitiative• Prompted when EE Managerheard about utility incentives froma peer
  • 39. Case Study Deep Dive: Silver BeautyLocation Chicago, ILBusiness Builds and leases warehouses in Chicago areaFacility type: Dry warehouseFacility Size 177,413 square feetOperating Hours 24x7Previous Lighting 1,000 Watt Metal HalideIssues • Energy and maintenance expenses• Light levels• Noise levels (humming)39
  • 40. Silver Beauty: Requirements & AlternativesRequirements• High light levels in both racked aisles and open spaces• Instant on/off – no warm-up time required• Daylight harvesting• Ability to fine tune/re-program lighting settings as facility setupchanges – without touching each fixture• Noise-free• Sound investment• No maintenance or re-lamping expenses• Rapid payback• Long lifetimeLighting Alternatives Considered• None40
  • 41. Silver Beauty Results• 92% lighting energy savings• From $78,335 to $4,078/year• 1,237,626 kWh savings per year• Excellent light levels across the facility• Today in Warehouse #5, LightRules reportsoccupancy of 30% in well-traveled aisles and10-15% elsewhere• Facility manager discovered in his otherfacility, Warehouse #6, that his T5 fixtures(with occupancy sensors) were experiencingquick lamp life degradation due to frequentcycling – even with cold weather ballasts41
  • 42. An Inside Look at Silver Beauty’s Incentive• Presenting: Mark Allen, Energy Engineer, ComEd• ComEd’s Smart Ideas for your Business Program• Prescriptive vs. custom incentives• Custom incentive requirements• LightRules vs. the ComEd meter42
  • 43. The Future of Intelligent LED Lighting• Further customization• Integration with other key technologies• Cloud management• Automated demand response• Expansion into all commercial and industrial applications43
  • 44. From the Industrial Perspective• Not a lot of time to assess lots of products and technologies• See energy provider as trustworthy source of information• Some have EE/sustainability managers but most don’t• Many need a project payback of 2 years or less – incentivesmay make or break it• May be trying to comply with corporate EE/sustainabilitydirectives• May be on tight deadlines44
  • 45. What Can Utilities Do?1. Grant custom incentives that bring projects to ≤2 year payback2. Sponsor a test trial to monitor energy reduction3. Train energy efficiency team and trade allies in new technology4. Next step – installation site visit coordinated by MEEA45
  • 46. Efficiency Flexibility Reliability SavingsIntelligence Doesn’t Cost MoreIt Gives You More46Mike FeinsteinVice President, Sales & 545-1663