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Re-Lamping of Casting Manufacturing Facility Results in Reduced Energy Costs and Increase in Parts Inspection Efficiency


Manufacturing facility realizes energy savings and increased productivity resulting from LED re-lamping project.


Manufacturer of airfoil castings for turbine engine applications that are used specifically in commercial and military jet engines, helicopters and industrial gas turbines.


The T8 lamps that were currently installed in the factory needed to be replaced frequently. This slowed down production and hindered parts inspection. The manufacturer was looking to upgrade their lighting either with completely new fixtures or a LED re-lamping in current fixtures.


The manufacturing facility had T8 shatter resistant lamps and they were looking to replace them with LED lamps that were DesignLights Consortium (DLC) rated for clean environments. They were also looking for a way to save money on their utility bills. Additionally, they wanted to improve their work station lighting so their team could work more efficiently.


Prior to making a final decision, test lamps were installed in ¼ of the plant. This allowed the customer to see if the lighting fit their needs. To help save money, we worked together to formulate a plan to re-lamp existing lighting fixtures with LED 4ft and 8ft DLC rated lamps. A recycling program for the T8 lamps was also implemented.


Upgrading the lighting to LED lamp decreased utility costs and production downtime. By changing to LED lamps there was an increase in lumens at each inspection station which assisted with increased efficiency. With reduced wattage usage per lamp, the manufacturing facility is saving $4,316.43 per year in energy costs. The ROI of the total project was 2.1 years. The upgrade was so successful they are looking to duplicate the re-lamping project in their other facilities.


  • Test Lamps
  • LED Lamps
  • Recycling Services
  • ROI Analysis