American Green Lights receives 2017 IES Award of Merit for custom retrofits for Tyson Fp

 IES Awards American Green Lights for Custom LED Retrofits developed for Tyson Foods.

Tyson Facility upgraded to LED

Case Study: 

Tyson Foods Discovery Center, Downers Grove, IL
Versafit Custom LED Retrofit
Convert 480 Watt Metal Halide to 144 Watts LED 

Results

580% increase in per-watt performance

Increase foot candles by 75%

Decrease electricity consumption by 70%.

American Green Lights of San Diego, CA was recognized by the Illuminating Engineering Society (IES) with its 2017 Illumination Award of Merit.  The project that earned the award was a custom LED retrofit module that resulted in a 580% increase in lighting performance compared to the traditional Metal Halide Lights.

Tyson Foods Discovery Center.  Downers Grove, IL

Dave Segerson, Regional Director and local agent for American Green Lights, worked closely with Tyson's Kent Bearson- Director of Process Engineering, Jeff Fisher-Maintenance Manager, and Beata Kieltyka-Sr. Manager Pilot Plant to identify problems and look for opportunities for increased productivity and reduced electricity consumption and downtime.

Problem Identification

• High Electricity Cost 
• 24/7 operations
• 480 Watts of electricity per fixture
• High Maintenance Cost 
• 1 or more lamp replacements per year to maintain minimum OSHA foot candle levels
• ballast replacement every 2-3 years
• Special lifts required to work around existing machinery
•  Lost Productivity
• Long restart times of Metal Halide costs 15-20 minutes downtime for each intermittent power outage.  Several occurances per year leads to hundreds of thousands of dollars in lost productivity per year. 
• Production shut-down for maintenance
• High cost of new fixtures
• NSF Certified fixtures are expensive
• Installation of new fixtures to meet NSF requirements is expensive 

Solution Development

• Assess current fixture issues
• Develop Solution ideas and designs
• Hand made prototypes for verification of fit and performance
• Modifications for reduced installation time
• Tweak designs for manufacturability
• Manufacturing
• Delivery and Installation
• Measurement of results

Final Solution

• 144 Watts LED compared to 480W Metal Halide
• Simple installation requires only minutes to install
• 100,000+ hour lifetime compared to 8,000-12,000 hours for Metal Halide
• Instant-on, Instant Restart eliminates Downtime
• 95 CRI Color Rendering Index improves color accuracy for better quality control

Increased foot-candles by 75% and reduced electricity usage by 70% for a 580% performance per watt improvement.

For more information about American Green Lights or custom retrofits, visit www.americangreenlights.com or send inquiry to info@americangreenlights.com.

UIC upgrades Gymnasium with Induction High Bay Lights from American Green Lights

University of Illinois Chicago Uses Induction to reduce Electricity Expenses and Improve Light Quality

The tired old metal halide lighting in the university gymnasium was buzzing so loudly that we had to shout inside the gym just so we could hear each other talk---and we were the only two people in the gym!  The 198 metal halide lights were a maintenance nightmare.  The lumen degradation was such that some lamps needed to be replaced within 3 months of installation.  Some lamps had shifted in color to be virtually unusable.  The lights needed to withstand impact from activities including baseball strikes and volleyball strikes.

They had tested a number of LED fixtures and the cost was prohibitive for wide-spread deployment.  We were invited to offer a solution that would solve their problems, yet be cost effective.

 

American Green Lights assessed the situation and determined that we could reduce the electricity consumption and improve light quality with payback of just over 2 years.  They wanted to increase the light levels about 10%.  We conducted computer simulations of the gymnasium to identify the best combination of technology and wattage to solve the problem.  We chose 250 watt induction high bay lights to replace each 400 watt metal halide fixture.

 

The result was an increase in lighting levels from an average of 45 ft-candles to an average of 55 ft-candles on their standard courts, and an increase from 70 ft-candles to over 100 ft-candles on their championship courts.  We replaced the current fixtures one-for-one in the same locations.  The fixtures chosen  were configured with clear polycarbonate domed lenses and protected with wire guards.

With 100,000 hour lifetime and using 40% less electricity, the 45,000 watt reduction in electricity usage will save over $1million in electricity and maintenance over the 20 year lifetime of the fixtures.

 

“Our Facilities Management team did an excellent job vetting the potential technologies & suppliers for the PE gym project. Our installation of the INDUCTION fixtures from American Green Lights significantly reduced our energy & maintenance expenses while dramatically increasing the light output and performance. This retrofit will improve the end user experience while maximizing the university's investment. We couldn't be more satisfied"

    -Mark Donovan: Vice Chancellor for Administrative Services

“Not being familiar with INDUCTION technology caused some initial concern for me. However, once the installation started, it became obvious that we made the right decision~ brighter lights, no buzzing ballast noise, less heat eminating from the lamps, no flickering and instant-on light. Everyone that comes into the gym comments on the positive change. Based on our success with this project, we plan to relamp other areas of this & other facilities.”

--Bill Bavirsha: Associate Athletic Director / Director of Facilities

All phases of this project evolved as planned: the assessment>proposal>delivery timeframes, ease of installation, no damaged or defective fixtures and a light output that matches exactly to the American Green Light forecast. We were under a tight timeline due to previously planned activities in the facility. We accomplished my goal: a seamless, hassle-free building upgrade for all who enter this facility.
--Peter Martin: Project Manager, University of Illinois Chicago

Hampshire Farms Lights up with LED

HAMPSHIRE FARMS LIGHTS UP WITH LED 
Commercial Packager sees immediate savings and performance improvement.   Hampshire Farms supplies many of the largest home and garden centers with live plants.  During the peak season, they operate 24 hours a day, preparing plants for shipment to their customers.  They originally utilized 8 ft fluorescent fixtures, each with 2 lamps of 75 Watts per lamp.  American Green Lights installed 2 units of PerformaLUX 24Watt LED Utility Lights end-to-end and reduced the electricity consumption by 65% from 150Watt to 48 Watts.

PerformaLUX SL Series LED Shop Light

The result was improved lighting quality, improved visibility and reduced maintenance at a fraction of the electricity consumption.  Furthermore, since fluorescents lose most of their illumination when temperatures drop below 70 degrees Farenheit or above 80 degrees Farenheit, the consistent light output of the LEDs was noticably better during the cool spring temperatures of the Chicagoland area.

The installed fixtures were PerformaLUX SL-4L-GAM-24-24-60 Utility Shop lights from  American Green Lights.  The PerformaLUX fixtures features replaceable LED strips and LED drivers for maintainability, though the 50,000 hour lifetime will not require much maintenance for 10 plus years of operation at an average of 12 hours per day.  The 6000K color temperature provides daylight white lighting for improved visibility in high task areas where pneumatic tools and sharp instruments provide danger if the lighting is not adequate.

Wet Certified Lighting used in sprinkler and washdown areas.

As a living plant supplier, many areas require sprinklers and washdown activities.  The PerformaLUX wet certified IP65 lighting fixtures provided the ideal solution for these harsh environments.  These fixtures feature high impact ABS bodies with clear textured polycarbonate lenses for optimal light dispersion.  The silicon lens seal and sealed wire compression connector assure moisture does not enter the fixture, even under direct water spray.

“The American Green Lights Shop Light and Wet Certified LED fixtures converted sections of our facility from a poorly lit, potentially hazardous and productivity challenged environment to one with a noticeable improvement in light with a 65% reduction in energy and maintenance expense. The delivery, installation, rebate filing, light performance and general follow up couldn't have been better.”

--Brian Kiernan, General Manager, Hampshire Farms

Trinity Church LED retrofit reduces electricity 95%

Trinity Church 12W LED Retrofit Kit Replaces 300W Halogen
Saves 95% Electricity with Improved Light output

Trinity Church in New York City wanted to reduce energy expenses and reduce the frequency of lamp replacements. One big headache was a set of Halogen wall washers that they used to illuminate the foyer area of one of their office buildings.

These wall washers use 300W Halogen lamps, with rated lifetime of 2,000 hours, which needed to be replaced a couple of times a year. American Green Lights analyzed the current light fixtures and determined new generation LED Arrays were the best option.

The original fixture was tested. The 300W Halogen lamp consumed 224 Watts of electricity, and produced 6600 lux at 18 inches. 2700K color temperature LEDs were used to match the color of the halogen lamps. Utilizing light meters to match the current light output, high output LED arrays were installed on a custom heat sink and tested. Surprisingly, 4 units of 3 Watt arrays produced greater light output than the Halogen.

The photo above shows that the 12W LED is equal or better light output than the halogen.

Summary of results:

• Measured electricity consumption: 12.4W LED vs 224W halogen
• Measured Power Factor: .998 LED vs 1.0 Halogen
• Lamp Temperature: 47 degrees C LED vs. 300+ C halogen
• Light Output at 18 inches: 6600 lux LED vs 6200 lux halogen

LED information:

• 4 units of LED array modules of 3W-5W capability each, powered at 3W each (we underdrive each LED to extend product lifetime and minimize lumen degradation
• LED arrays rated for 119 degree C maximum operating temperature. Temperature measurements show operation with these heat sinks inside this fixture does not exceed 47 degrees C.
• Color Temperature: 2700K
• Color Rendering Index: 80+

For additional information, please contact American Green Lights at 858-547-8837 or at info@americangreenlights.com.

Induction vs HPS in Loading Dock

Induction vs High Pressure Sodium:

Michigan Plaza Completes Loading Dock Conversion

Michigan Plaza, in downtown Chicago used to have a dark and dingy loading dock. The orange glow of the lower streets of Chicago were implemented when the building was first erected and continued until American Green Lights introduced them to induction lighting.

We replaced 250W HPS lights with 150W Induction Lights.

The light quality improved. Security guards are delighted that the video feeds are much more clear and the color rendering of vehicles is much brighter. Drivers can more easily read their documents, and the ease of parking and loading is much improved.

Michigan plaza will save about $120 per year per light fixture in electricity savings, plus with the 100,000 hour lifetime, expects to save an average of $30 per year per fixture on maintenance costs. Payback is expected in less that 2.5 years. With the additional rebates from the power company, the payback is now less than 1.5 years!

150W Induction Dock Light from American Green Lights

New LED Utility/Shop Lights Available

New PerformaLUX LED Shop Lights Available

2 ft and 4 ft Utility/Shop lights now offered by American Green Lights under their PerformaLUX brand. 2 ft version retails for $109 and 4 ft version retails for $129.

The clean and simple design of the shop lights provide a no frills, utilitarian light source with half the electricity consumption of fluroescents lights. The LED lights contain no mercury and pose no hazardous chemical contamination risk, unlike the fluorescents.

The 12Watt 2 ft version produces 1200 lumens and the 24 Watt 4 ft version produces 2400 lumens of light output. Each 1200 lumens of directional light from the LEDs provides equivalent lighting to a 100W incandescent or one 2 ft high output fluorescent tube.

PerformaLUX is a trademark of American Green Lights and Hachipa Inc. San Diego, CA. www.performalux.com

NEW LED 2x2 Troffers for under $200

American Green Lights brings LED technology to the mainstream market, with three models of 2x2 an 2x4 series of suspended ceiling troffers for under $200. These troffers outperform their fluorescent counterparts by providing high lumen output and dramatic lifetime improvements of over 50,000 hours.

These new models are offered in 3000 lumen, 4000 lumen, 5000 lumen versions. Compare these to most other 2x2 troffers on the market which start at over $400 and only offer 1800 lumens!

Contact jimuno@americangreenlights.com for more information.