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Reprinted from Energy User News
Reprinted from Energy User News
Vol 22 No 11 • Nov 1997
Worker Feedback Creates Layout
that Uses 3,000 Fewer Ballasts

By KESSEL L. NELSON
      FOUNTAIN INN, S.C.

— In February, Delta Woodside Industries completed a lighting retrofit of its Beattie Textile Plant here that is expected to reduce the facility's overall energy consumption by 62 percent, saving the industrial end user over 4 million kilowatt hours per year.
      Funded by Delta Woodside's construction budget coffers, the retrofit cost approximately $331,000. The more efficient lighting system was designed and installed by local lighting contractor Mor-Lite Inc. According to project data released to EUN, the retrofit is expected to lower electric demand from 686 kilowatts (kw) to about 224 kw, a total reduction of 462 kw. The plant operates 24 hours per day, seven days a week. Based on a continuous operating schedule, Delta Woodside officials anticipate annual energy savings of 4,051,325 kwh — a cost savings of approximately $162,000 per year. The simple payback for this project is just over two years.
      More than 4,400 Slimline and high output industrial fluorescent fixtures were eliminated during the retrofit. Technicians installed 2,665 new eight-foot, single-lamp industrial fixtures from H.E. Williams, Carthage, MO, throughout the plant. Each fixture was fitted with a 95-watt, high output fluorescent tube from Philips Lighting Co., Somerset, NJ. The fixtures were fitted with custom-made specular silver reflectors of various

Beattie Textile Plant reduced its lighting load from 686 kW to 224 kW. Operating cost went from $240,493 to $78,441.

manufacturers, including 3M, Minneapolis; Metalloxyd Inc., Atlanta; Alanod Aluminum, Ennepetal, Germany; and Alcoa Brite Products, Norcross, GA. In a few cases, the placement of the textile equipment hindered fixture installation. In those instances the installers adjusted the reflectors in the fixtures to direct light onto critical areas along the production line. Technicians also installed about 1,400 high output electronic ballasts from MagneTek Lighting Products Group, Nashville, that are tandem-wired to the new fixtures.
      The Beattie Plant's new lighting arrangement uses 1,735 fewer lamps than the preretrofit design, a reduction of 40 percent. There are also 3,000 fewer ballasts in operation, a 70 percent reduction. Eldeco, a local electric contractor, managed the removal and recycling of the old lamps and PCB-laden ballasts

Textile Plant's Lighting Job to Save 4 MMkwh

      Huebner told EUN that the new lighting layout was developed with input from plant personnel and equipment manufacturers. Using equipment placement and employee suggestions as a guide, Huebner developed a fixture layout designed to provide maximum illumination, visual comfort, and safety. “In terms of lighting, the people who operate these machines know what they need,” Huebner said.
“These machines are very large; they're bolted to the floor so their placement is fixed. Most textile plants are designed with the same layout, so this lighting arrangement can be used in any number of facilities.”

“We built a wall down the length of the plant and installed the necessary power lines so that one side could maintain production while the other side was shut down and retrofitted.”

      “This was a massive undertaking. The Beattie Plant is a 400,000 square-foot facility,” explained John Hall, director of corporate engineering, Delta Woodside Industries. The plant's operating schedule presented a problem for the installers; plant production could not be stopped, so some unusual measures were taken. “Since we couldn't shut down the plant, we divided it in half. We built a wall down the length of the plant and installed the necessary power lines so that one side could maintain production while the other side was shut down and retrofitted.”
      Increased worker efficiency and productivity were among the non-energy-related byproducts created by the upgrades. “The new lighting system has not only helped reduce our operating costs, but improved the quality of our production. We always use premium equipment whenever possible,” Hall concluded.

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