Veeco Services, a leading, full-service logistics provider, boasts a 615,000 square foot warehouse in North Bergen, NJ. More than 14 football fields in size, Veeco’s warehouse is equipped with 117 dock doors and 34,000+ pallet locations, and the operation is unrivaled in speed and accuracy.
It became clear there were a variety of challenges with the warehouse lighting after National E Solution (NES), an energy management company and Enlighted partner, conducted a lighting audit in January 2019. The current high-intensity discharge (HID) fixtures were emitting poor lighting levels, wasting energy and were expensive to maintain. Additionally, Veeco upgraded to a new racking system that added more rows and narrow aisles.
The old lighting included 366 HID and fluorescent lighting fixtures that drew a 150,825-watt load. Based on the warehouse’s operating hours, the lighting was using 1,062,500 kWh annually to deliver poor lighting levels.
Tackling the warehouse redesign
National E Solution redesigned the lighting for the new aisles to improve foot-candles and the quality of lighting while reducing the operating cost and maintenance. To achieve optimal lighting levels, they selected 168-watt high bay LEDs that produced 23,000 lumens each with a color temperature of 5000 Kelvin. The new aisle lighting was created to achieve lighting levels that met the Illumination Engineering Society minimum standard for this work application. The customer’s target was an average of 25- to 30-foot candles.
The new design gave us the ability to space the new fixtures as far apart as possible and still achieve the ambient lighting level results we wanted, reducing the total number of LED fixtures needed. It was critical to the success of this project that we installed a high-quality lighting control system. We selected Enlighted to further support the needs of the warehouse and maximize energy savings.
Ray Sizer, President of National E Solutions
Each light fixture was equipped with a smart sensor. Built on the leading Internet of Things (IoT) architecture, the Enlighted system consists of a network of patented sensors, connected to an advanced analytics platform. Data is collected 65 times per second to monitor environmental and occupancy changes and adjust lighting in real time.
With the Enlighted system, each fixture has its own address, allowing us to group fixtures as needed. For example, when the Veeco staff is working in an aisle, we wanted the aisle behind that to be the backlight for safety reasons, which we were able to accomplish. Because of the density of the sensors, occupancy sensing is extremely accurate. It allowed us to further reduce energy use and unnecessary wear and tear on the lighting fixtures.
Veeco was able to fine-tune the power output to the fixtures using the Enlighted control system. This allowed Veeco to reduce overall energy use and still achieve acceptable lighting levels. The team set the lighting system power load to 75 percent of the rated LED fixture load, which still provided excellent lighting for the warehouse crew. This reduced each fixture from a 168-watt load to 126-watts. Reducing the light output also extends the life of the LEDs and drivers far beyond their rated life. Multiply the savings of 388 fixtures for 365 days and the Enlighted systems begins to deliver real dollars saved.
We can group the fixtures and control them beyond a traditional on/off occupancy sensor. This allows for entire aisles to be lit only while in use for optimal savings and safety. The system is very easy to work with. I can easily highlight the fixtures, make changes to the lighting groups and also update the lighting profiles. The ability to upgrade the Enlighted system and unlock additional IoT features like facility mapping and asset tracking is a win. While we are not currently using these features, we have the ability to upgrade when the time is right.
Orlando Ortiz, Director of IT, Veeco
After one year in operation, Veeco reduced its lighting energy load by 59 percent by merely converting to LED fixtures, even though the fixture quantity increased. By controlling the lighting with Enlighted’s system, the facility achieved an 804,725 kWh savings for the year that resulted in reducing energy costs by $122,318, a 75 percent total reduction in energy compared to the previous system. The new lighting and wireless control system reduced greenhouse gases and CO2 emissions by 554 metric ton, equivalent to removing 93 cars from the road annually. Veeco will save an additional $14,000 per year on annual lighting maintenance.