Manufacturers Best Practice Guide

Lighting: Energy Use Basics

If advanced lighting technologies were fully applied in the United States, the resulting electricity savings would negate the need for 120 1,000-megawatt power plants. Doing this would save ratepayers $30 billion a year just on the cost of operating those plants (never mind the cost of building them). (Rocky Mountain Institute)

Lighting accounts for 20% of US electrical use, nearly 7% of electricity use in industrial and manufacturing facilities, and 30% of commercial buildings' energy use. Upgrading the lighting system is one of the best energy efficiency measures a facility can undertake in terms of payback, ease of implementation, energy savings and secondary benefits such as reduced GHG emissions and increased employee productivity. Lighting upgrades can usually be done in-house as part of routine maintenance, making for easy, non-disruptive, low-risk investments with relatively quick payback rates.

Revamping the lighting at your industrial facility is a simple and direct way to introduce an energy team and company executives to energy efficiency and the corresponding 50% to 90% savings. Most companies are able to save on lighting costs with basic, low-cost changes such as replacing incandescent bulbs with CFLs and LEDs. Eliminating inefficient lighting will also reduce interior temperatures, lower cooling bills, and improve lighting quality.

Lighting technologies are complemented by energy management systems that engage motion sensors and timers to reduce the energy drain when areas are not in use or when there is sufficient natural light. Of course, taking advantage of natural light is the first and best option when possible. A single three-by-five-foot window in direct sunlight lets in more light than is emitted by 100 standard 60-watt incandescent bulbs.

Daylighting a warehouseView Details.


The financial payback for improving lighting efficiency can be as little as 6 to 9 months, particularly when considering the numerous federal and state incentives and rebates currently available. After initial payback, all of your savings are just money in the bank.

Leading by Example: General Mills

With over 1 million sq. ft. at two California distribution facilities, General Mills had good reason to make energy-saving upgrades to its lighting. By replacing 847 metal halide fixtures, using 465 watts each, with 206-watt T8 fluorescent fixtures, they were able to cut 45% of their energy use. Combining that with occupancy sensors for further conservation, General Mills was able to save 1,890,000 kWh and $269,000 per year. With $101,000 in rebates from Southern California Edison and Pacific Gas and Electric, General Mills paid back the cost of investment in less than 1 year. Better lighting also improved productivity and worker morale for a true win-win project.