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
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| 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.
