Warehouses and Distribution

Eco has successfully completed hundreds of projects in the Distribution Center environment involving millions of square feet of total space. Our experience offers some critical insights and key learnings about energy efficient lighting projects in these types of facility.

Temperature Fluctuation

Important criteria when dealing with unheated distribution centers, especially freight terminals and docks is temperature and the effects that extreme cold/hot temperatures may have on the light output. Additionally, the mounting heights of fixtures will effect the light distribution. In both cases, it's imperative that the design team selects the correct "lighting system", i.e., lamp, ballast, fixture, and sensor.

Ambient Sensors

Ambient photocell sensors can automatically control the ‘‘off/on” function for many types of lighting, thus producing another source of energy savings. Eco engineers and auditors explore what areas within the terminals can have "lights off" and incorporate specific recommendations regarding ambient sensor technology where appropriate. Special attention is placed on evaluating security and safety issues while engineering the correct and financially prudent sensor solution. Temperature is an additional factor as our engineers consider the potential cold temperature of an area before programming the sensor to shut the lights down.

Motion Sensors

In warehouse areas without 24x7 activity, motion sensors conserve energy by shutting lights down when there is no activity. Our sensor studies using light loggers have found energy savings of up to 78% in distribution centers where local Managers thought they were relatively busy! Safety issues must be elevated to paramount importance when considering this technology as some areas in the facility, like the maintenance bays, are unlikely candidates to install motion sensors.

Fixture Choice

The most important decision you will make is the proper fixture design for your space. This choice will determine whether your light is spread evenly over the vertical and horizontal areas being measured, or whether you get “hot spots”. Should it be a narrow, medium, or wide design; T8 or T5, amalgam lamps or regular lamps; is a mirror or other anodized polished aluminum surface required; should the fixture have a lens, or cage; should the fixture be aluminum, or steel; should the ballast be mounted inside, or on top of the fixture to manage heat, etc. All of these factors should be considered when you are looking at the proposed CAD drawings showing the light levels.

Maintenance Bays

Many warehouse and distribution centers have an area dedicated to maintenance and repair of their equipment. The location of the lighting in the maintenance bay is primarily in between the rows where vehicle traffic occurs. Proper location of fixtures in this case helps insure sufficient lighting to maximize accuracy and productivity of maintenance work while optimizing energy efficiency.

MRO Savings

Warehouse and Distribution Center environments often provide an opportunity for significant savings in Maintenance, Repair and Operating expenses (MRO) following a lighting upgrade. These savings are not only real; they can carry a significant impact on the financial payback analysis associated with the project – since the new lamps and ballasts will operate for up to three years or longer without needing any maintenance . Eco works closely with our clients to calculate the current expense in maintaining and repairing the existing lighting systems and then we conservatively estimate the savings from inventory management and labor costs post-project.

Total Building Savings

While the warehouse, distribution center and loading docks of these facilities are often fairly uniform, the buildings often contain office and employee space that is unique. If these add-on spaces are audited and evaluated for a lighting upgrade project, the extra square footage may produce added energy savings. The solution designed for these areas is likely to be very different from the warehouse spaces. For example, while it may be desirable to use a high lumen lamp in the warehouse high bay fixtures, it may be desirable to use a new energy saving 28 watt lamp in the offices. We look carefully at maintenance practices to ensure our design will be easily maintained so office lamps won’t get mixed up with warehouse lamps. Eco has experience with many projects fitting this situation and has seen the added impact of the non-warehouse square footage create the difference between an acceptable project payback and a borderline financial business case. Additionally, energy rebates and tax credits – like those available from EPAct – may allow for different methods of computing savings based on partial versus total building solutions.

Key Clients: Warehouse and Distribution Centers

FedEx Freight - Case Study
Dell Computer - Case Study
AAA Cooper
United Parcel Service
EXEL - Reference Letter
Yellow-Roadway Freight
Coca Cola - Reference Letter
Pepsi-Cola General Bottlers
7-up Bottling
Aramark Uniform Service
MTD - Reference Letter