Commercial Architecture November 2017 - 43

PROJECT

lighting

Assembly-Plant Lighting Retrofit
TLEDs save more than $300,000 annually in energy and maintenance.

A

s energy optimization leader at the

to tubular LED in the body shop and through-

4.7-million-sq.-ft. General Motors'

out general assembly, material storage, kitting,

Orion Assembly plant in Lake Ori-

paint shop, final assembly, trim shop, mainte-

on, MI, Edward Fish is responsible for driving

nance areas, and administratio- building office

and supporting corporate energy conserva-

areas," Fish explained.

tion initiatives in GM's manufacturing and
non-manufacturing facilities.

Contactors on the energy-management system serve as master controls for large banks of

The facility was built in 1983 and is where

lighting fixtures throughout the plant. Some

the Chevrolet Sonic and the Chevrolet Bolt

areas use occupancy sensors on individual fix-

EV are assembled. It is the first GM facility to

tures for improved control, which provide ad-

receive the Clean Corporate Citizen designa-

ditional energy savings.

tion by the state. In addition, it received a U.S.

Starco lamps were installed in retrofitted

Environmental Protection Agency's Green

TCP Elite six-lamp fixtures in the manufactur-

Power Leadership Award for 2016.

ing space. Starco lamps were also fitted to two-

With linear fluorescent lamps from various

lamp open-task line lights used for line light-

manufacturers approaching end of life, Fish

ing.

and his team performed an extensive evalua-

accomplished in 2 x 2 and 2 x 4-ft. troffers.

Office

lighting

retrofitting

was

tion of various tubular LED (TLED) product

The only issue with the project was employ-

manufacturers. The company performed a

ee feedback that 18-W lamps initially installed

technical review, followed by an on-site prod-

in the office areas were too bright. These areas

uct evaluation to assess performance. After the

were re-lamped with 15-W lamps to achieve a

studies, Fish selected products from Starco

more comfortable light level.

Lighting, Buffalo, NY.

Overall, light levels with the LED lamps

"The business case for the corporate ener-

were consistent with linear fluorescent. Later

gy-conservation project was based on engineer-

phases of the project used an improved-tech-

ing calculations, which demonstrated a simple

nology Starco lamp with increased lumen out-

two-year payback from energy savings," Fish

put and higher efficacy. This increased initial

stated.

light levels from 29 footcandles to 34 footcan-

Starco's extensive line of 2-, 3-, 4-, and 8-ft.

dles and assured that lighting intensities re-

product lengths and wattages, ranging from 9

main adequate even at the end of the lamp's

W in a 2-ft. tube to 36 W in an 8-ft. tube, was

life.

first tested at the GM Components Holdings
facility in Grand Rapids, MI.

"The Starco lamp results in a 40% reduc-

DES Electrical Services of Detroit was

spaces, and a 54% reduction in office areas,"
Fish said. "We expect to save just over $300,000

cess to some areas without having an impact on

annually in energy and maintenance costs

production required good communication,

from this lighting change."

planning, and coordination with tech support

The tubes are backed with an uncondition-

teams, specifically above the robotic welding

al 8-year warranty. The shatterproof lamps are

cells in the body shop.

designed for the challenges of energy reduction

Work was done in various phases. Ceiling

and industrial safety compliance. The polycar-

heights ranged from 12 ft. in office areas to ap-

bonate circular lensing is shatterproof and

proximately 24 ft. in manufacturing areas. The

doesn't require any extra protection. Starco's

retrofitting process was accomplished primari-

LED driver system withstands extensive surge

ly during non-production hours, but some

voltage and high ambient temperatures and

work was performed during normal business

works seamlessly with the Fast-Fuse socket kit.

"We upgraded areas from linear fluorescent

Below. The Orion plant is where the Chevrolet Sonic and the Chevrolet Bolt EV are assembled.
It is the first GM facility to receive the Clean Corporate Citizen designation by the State of
Michigan.

tion in energy consumption in manufacturing

brought in to perform the retrofit. Gaining ac-

hours.

Above. Starco lamps were installed in retrofitted TCP Elite six-lamp fixtures in the manufacturing space at GM's Orion Assembly plant. Lamps were also fitted to two-lamp open-task line
lights used for assembly-line lighting.

Starco products have been used to retrofit

Want more information? To download the information listed below, visit
commercialarchitecturemagazine.com/1711starco

Circle 11 on the Reader
Service Card.

Learn more about the FastFuse socket kit.

Learn more about Starco
TLEDs.

17 General Motors plants in the U.S. CA
commercialarchitecturemagazine.com

NOVEMBER 2017

COMMERCI A L A RCHI T EC T URE

43


http://www.commercialarchitecturemagazine.com/1711starco http://www.commercialarchitecturemagazine.com

Table of Contents for the Digital Edition of Commercial Architecture November 2017

The Architects
Preserve Or Restore?
Adaptive Reuse
Light, Sound Contribute to Comforting Experience
Access Flooring Saves Energy, Improves IAQ
Green Walls Welcome Restaurant Guests
High-Profile Ceilings
HVAC System Redirects Convent Resources
Lighting Complements 'Study Cascade' Design
Assembly-Plant Lighting Retrofit
Brewing Up Lighting
Have It All: Quality, Comfort, Efficiency, Cost Savings
Translucent Facade Highlights Learning
Historical Details, High-Performance Windows
Protecting And Enlightening History
Most-Wired Hospital Saves Big
Showcase
Commercial Architecture November 2017 - Cover1
Commercial Architecture November 2017 - Cover2
Commercial Architecture November 2017 - 1
Commercial Architecture November 2017 - 2
Commercial Architecture November 2017 - 3
Commercial Architecture November 2017 - 4
Commercial Architecture November 2017 - 5
Commercial Architecture November 2017 - The Architects
Commercial Architecture November 2017 - 7
Commercial Architecture November 2017 - Preserve Or Restore?
Commercial Architecture November 2017 - 9
Commercial Architecture November 2017 - 10
Commercial Architecture November 2017 - 11
Commercial Architecture November 2017 - 12
Commercial Architecture November 2017 - 13
Commercial Architecture November 2017 - 14
Commercial Architecture November 2017 - 15
Commercial Architecture November 2017 - Adaptive Reuse
Commercial Architecture November 2017 - 17
Commercial Architecture November 2017 - 18
Commercial Architecture November 2017 - 19
Commercial Architecture November 2017 - 20
Commercial Architecture November 2017 - 21
Commercial Architecture November 2017 - Light, Sound Contribute to Comforting Experience
Commercial Architecture November 2017 - 23
Commercial Architecture November 2017 - Access Flooring Saves Energy, Improves IAQ
Commercial Architecture November 2017 - 25
Commercial Architecture November 2017 - Green Walls Welcome Restaurant Guests
Commercial Architecture November 2017 - 27
Commercial Architecture November 2017 - High-Profile Ceilings
Commercial Architecture November 2017 - 29
Commercial Architecture November 2017 - 30
Commercial Architecture November 2017 - 31
Commercial Architecture November 2017 - 32
Commercial Architecture November 2017 - 35
Commercial Architecture November 2017 - HVAC System Redirects Convent Resources
Commercial Architecture November 2017 - 37
Commercial Architecture November 2017 - 38
Commercial Architecture November 2017 - 39
Commercial Architecture November 2017 - 40
Commercial Architecture November 2017 - Lighting Complements 'Study Cascade' Design
Commercial Architecture November 2017 - 42
Commercial Architecture November 2017 - Assembly-Plant Lighting Retrofit
Commercial Architecture November 2017 - Brewing Up Lighting
Commercial Architecture November 2017 - 45
Commercial Architecture November 2017 - 46
Commercial Architecture November 2017 - 47
Commercial Architecture November 2017 - Have It All: Quality, Comfort, Efficiency, Cost Savings
Commercial Architecture November 2017 - 49
Commercial Architecture November 2017 - 50
Commercial Architecture November 2017 - 51
Commercial Architecture November 2017 - 52
Commercial Architecture November 2017 - 53
Commercial Architecture November 2017 - Translucent Facade Highlights Learning
Commercial Architecture November 2017 - 55
Commercial Architecture November 2017 - Historical Details, High-Performance Windows
Commercial Architecture November 2017 - 57
Commercial Architecture November 2017 - Protecting And Enlightening History
Commercial Architecture November 2017 - 59
Commercial Architecture November 2017 - 60
Commercial Architecture November 2017 - Most-Wired Hospital Saves Big
Commercial Architecture November 2017 - 62
Commercial Architecture November 2017 - 63
Commercial Architecture November 2017 - Showcase
Commercial Architecture November 2017 - 65
Commercial Architecture November 2017 - 66
Commercial Architecture November 2017 - Cover3
Commercial Architecture November 2017 - Cover4
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