EV Logistics

"Since we installed T5 high-output fluorescents with occupancy controls in our warehouse, not only has electricity consumption gone down, but lighting levels have dramatically improved, resulting in fewer errors, improved working conditions and greater productivity by our employees."

— Dave Martin, Director of Operations, EV Logistics

The situation

EV Logistics is a joint venture between Exel Logistics and Versacold, two of the world's leading logistics companies. The company operates two warehouses in the Lower Mainland: a 156,000-square-foot perishable facility in Abbotsford and a 478,000-square-foot ambient dry storage facility in Langley. The two distribution centres supply one of western Canada's largest grocery retailers.

The Langley warehouse is one of the largest of its kind in the province. The facility was lit with 400-watt high-intensity discharge pulse-start metal halide luminaires, which were kept on 24 hours a day, seven days a week. The existing lighting was at the end of its lamp life and a decision had to be made whether to re-lamp or explore other potential lighting options. The company realized that better lighting could reduce operating costs and product selection errors, with the added benefit of improved safety and productivity. EV Logistics decided to test a number of fixtures to find a solution that would improve the energy efficiency and lighting quality of the facility.

The solution

BC Hydro, EV Logistics and several lighting vendors set up an unofficial demonstration project. Seven high-bay lighting options were installed in test aisles in the warehouse and then evaluated for technical and financial feasibility compared with the existing pulse start metal halide lighting system. The use of lighting sensors to turn off lights in unoccupied warehouse aisles was also integrated into the design.

Following the demonstration, various options were proposed to show how the technology would work in the facility, the potential payback and the incentive options available. This study showed that new lighting using T5 high-output (HO) fluorescents with occupancy controls would dramatically reduce electricity consumption. As a Power Smart Partner through VersaCold since 2002, EV Logistics was eligible to apply for financial incentives that would assist with project implementation and reduce the project payback to less than one year. EV Logistics senior management approved the project and it was carried out in 2006.

The retrofit involved:

• Replacing 895 existing 400-watt pulse-start metal halide lamps with 895, 228-watt, four-lamp T5-HO fluorescent high-bay luminaires throughout the warehouse
• Installing occupancy sensor controls with two occupancy sensors per aisle (one at each end)

EV Logistics has been so pleased with the results of the retrofit that they are considering a re-lamping project in the mezzanine area of the Langley warehouse. The project would involve replacing the existing 32-watt T8 lamps with 30-watt energy-saving T8 lamps. They are also looking at re-lamping the T5 technology at the Abbotsford facility. This project would involve a similar technology with fixtures designed specifically for the colder environment.

The benefits

Electricity savings
The lighting retrofit is saving EV Logistics 2.3 gigawatt hours of electricity, or $128,000, each year.

Reduced maintenance costs
Based on 12 hours of continuous operation, T5-HO lamps have a longer life – between 24,000 and 30,000 hours, depending on the manufacturer – compared with approximately 20,000 hours for a pulse-start metal halide lamp. The longer lamp life of T5-HO lamps increases the re-lamping interval, thereby reducing labour and maintenance costs. Additionally, the sustained light output of T5-HO lamps requires fewer lamps to provide the same level of light.

Improved lighting quality and employee satisfaction
Improved vertical light uniformity provides light where needed to warehouse employees. Staff report better working conditions and management is pleased that the T5-HO lights start up immediately when used with the sensors.