GUIDING LIGHT

As for many manufacturing facilities, rising energy costs were becoming an increasing problem for Wastequip, Inc. (Winamac, IN). Although Wastequip had previously implemented various strategies and products to reduce and conserve energy, the company was looking for additional ways to cut costs. Wastequip was using older high pressure sodium, metal halide lighting that provided dim work areas and required costly maintenance, and was interested in upgrading to energy efficient, low maintenance lighting.

Michael Dees, the director of manufacturing, engaged the facility in an energy audit with Energy Management Systems (EMS; Elkhart, IN). "Our business has been significantly impacted by the increases in energy costs," says Dees. "Additionally, we were not content with our current lighting systems, especially the amount of light output compared to the cost of maintenance and energy use."

Over the course of six weeks, the company analyzed current lighting and completed installation of energy efficient lighting and motion sensors. "The entire process required minimal involvement from our staff and was absolutely seamless and non-disruptive to production," remarked Dees, regarding the lighting upgrades. The energy audit uncovered problems with in the current lighting including:

• ?The discovery of older-style lights that used too much energy.
• ?The inefficient lights also were outputting approximately 30 percent of the light as when they were new. Wastequip was paying twice as much for half the light.
• ?EMS analyzed the daily tasks in the facility and discovered several low traffic areas in the plant that were constantly lit, wasting energy when not in use. More importantly, EMS discovered very dark areas that were occasionally used, posing a safety issue for employees entering those areas.

With little effort and minimal investment, Wastequip quickly saved significant amounts of energy and enjoyed a cost savings each month by upgrading older, dimmer lights to energy efficient lights and installing motion sensors to control lights throughout the plant. "It was well worth the investment," adds Dees. Wastequip immediately began saving money on monthly light bills in the initial phase of their energy upgrades. This included annual savings of more than $50,000 (or 61 percent) annually for just one facility. An EPACT 2005 Federal deduction added another $48,720 in savings through a one-time tax deduction.

By using energy efficient lighting and motion sensor controls, Wastequip–Indiana significantly reduced air pollution by more than a thousand tons a year or the equivalence of 3,256 cars over the next 20 years. According to Dees, "The automated sensors to control lights have improved safety, keeping employees out of the dark as they walk into low traffic areas. Our employees are pleased with a brighter work environment too."

For more information visit Energy Management Systems, 53850 North Park Avenue, Elkhart, IN 46514, 219-262-2993, Fax: 219-262-8667, www.energymanagement.com.