The Woodbridge Group is a manufacturer of innovative urethane and particle foam technologies serving the automotive, commercial and recreational vehicle industries. Their 250,000-square-foot Lansing facility handles contract assembly for General Motors. Interested in upgrading to LED fixtures, The Woodbridge Group’s leadership team was unable to find a solution that met their application and financial requirements. With a large focus on health, safety and energy conservation, they were seeking for an LED lighting solution that would increase light levels in their facility and enhance their employee’s working environment while reducing operating costs and energy consumption. Flex’s Essentials Series 4.0 LED high bays proved to meet all those requirements.
As a global company, The Woodbridge Group requires any facility improvement project to meet a 2-year payback window.
“We’ve been looking at LED lighting for a long time and tested some fixtures here and there. We could see the benefits as far as the quality of the light and energy usage reduced but they did not meet our 2-year payback requirement,” according to Scott Moore, Engineering Manager of The Woodbridge Group.
LED High Bays
Future Energy Group, a Flex Lighting Solutions partner, conducted a digital precision survey of The Woodbridge Group’s Lansing facility. Their recommendations were in alignment with the leadership team’s energy management conservation initiative. The results of that analysis proved there was a huge opportunity for energy savings and the Essentials Series 4.0 LED high bays from Flex Lighting Solutions were able to meet all their requirements, including the 2-year payback. The energy efficiency, cost savings and the 10-year warranty of the Flex Lighting Solutions LED high bays impressed the leadership team at The Woodbridge Group. This allowed the facility to finally move forward with their LED upgrade project.
”It wasn’t until I met Future Energy Group, they did a whole facility energy overlay and walked me through everything, then we really saw how big the savings were with the right LED lighting fixtures,” said Scott Moore.
The Woodbridge Group handled the installation of the project with their internal maintenance and facility teams. They replaced 621 6-lamp T8 fluorescent lighting fixtures with 621 Essentials Series 4.0 LED high bays.
The high efficiency of these new Flex LED high bays combined with the added savings from their integrated occupancy sensors, helped The Woodbridge Group achieve 73% energy savings.
“We wanted to make sure we increased the savings as much as we could and Flex’s LED high bays accomplished that,” said Sam DiNello.
Based on the operating hours of this facility, it is estimated The Woodbridge Group will save $83,890 per year in their utility bill and meet their two-year payback requirement. Besides saving energy, The Woodbridge Group wanted to increase the light levels near their operators. The brighter output and higher light quality of the Essentials Series 4.0 LED high bays allowed them to significantly increase the foot-candle readings in those task lighting areas which improves visibility and reduces errors. The field adjustable rotating modules are a distinctive feature of the Essentials Series 4.0 that allows to optimize the light distribution in the field to fit the facility and application requirements. This allowed The Woodbridge Group to provide directional lighting for their operators, improving productivity and creating a safer environment for their 300+ employees.