Case Study: Manufacturing Facility LED Retrofit
Cut energy, reduce cooling Load, improve light quality and safety, and unlock rebates.
Facility Overview
- Type: Large automotive component manufacturing plant
- Size: 100,000 sq. ft.
- Existing: 400W Metal Halide (HID) High Bays (250 fixtures)
- Operating Hours: 18 hrs/day, 6 days/week (~5,616 hrs/year)
Energy Savings
Baseline (HID): ~640,000 kWh/year
LED Retrofit: ~230,000 kWh/year
~410,000 kWh/year saved
≈ $49,000/year (@ $0.12/kWh)
≈ $49,000/year (@ $0.12/kWh)
HVAC Savings
LED high-bays reduce heat output by ~60%, lowering cooling load.
~$3,000/year
Estimated additional HVAC savings
Estimated additional HVAC savings
Maintenance (Legacy HID)
- ~15,000 hr life (re-lamp ~2.5 years)
- ~$7,000/year maintenance
- Warranty: 2–3 years
Maintenance (LED High-Bay)
- ~100,000 hr life (~18+ years)
- ~$500/year maintenance
- Warranty: 5–10 years
Other Benefits of LED
Improved visibility (higher CRI)
Instant on/off (no warm-up)
Reduced electrical load
Lower insurance risk (less heat/glass)
Utility Rebates
DTE Energy & Consumers Energy offer rebates for all business sizes.
Typical high-bay rebates: $50–$100 per fixture, often covering
20–40% of project costs.
ROI Example
- Project Cost (after rebates): ~$100,000
- Total Annual Savings: ~$58,500 (energy + HVAC + maintenance)
- Simple Payback: ~1.7 years
- ROI over 10 years: ~485%
Summary
- Energy Use: ~640,000 → ~230,000 kWh/yr (64% less)
- Annual Cost: ~$77,000 → ~$28,000 (save ~$49,000)
- Maintenance: ~$7,000 → ~$500/yr
- HVAC Load: High → Low
- Fixture Life: ~3 yrs → ~18+ yrs
- Warranty: 2–3 yrs → 5–10 yrs
We would Love to Make Your Facility Our Next Case Study!
Ready to see if LED retrofits make sense for your facility?
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