LED Lighting Improvements at Arconic
Project Overview
Woodstone Energy, LLC (Woodstone) along with Stones River Electric and Accendo Lighting were selected to execute a comprehensive LED lighting upgrade at Arconic’s Cleveland, OH manufacturing facility. The project aimed to enhance energy efficiency, reduce operational costs, and improve overall lighting quality across the facility. This initiative included the installation of energy-efficient LED lighting and motion sensors in warehouse areas, as well as LED tube replacements in office spaces.
Project Details
- Contract Award Date: February 10, 2017
- Scheduled Completion Date: December 31, 2017
- Actual Completion Date: November 30, 2017 (One month ahead of schedule)
- Facility Type: Manufacturing
- Number of Buildings: 14
- Operating Hours: 24/7/365
Energy & Financial Impact
- Annual Energy Reduction: 11,417,807 kWh or 38,929 MMBTU
- Total Project Investment: $5,933,303.00
- Annual Guaranteed Savings: $655,363.36
- Annual Delivered Savings: $754,484.23
- Projected 10-Year Positive Cash Flow: $1,081,390.73
- Actual 10-Year Delivered Cash Flow: $2,083,239.14
CO2 Emission Reduction
7,392 metric tons
Total Energy Reduction
11,471,807 kWh
10 YearPositive Cashflow
$2,083,239.14 beating project estimates by nearly 100%
Woodstone provided a turnkey lighting installation with a 10-year maintenance agreement and structured project financing, allowing Arconic to fund the investment through realized energy savings.
Despite an aggressive installation schedule, 7,615 fixtures were successfully installed in under 10 months, with the project delivered one month ahead of schedule. Notably, the project exceeded the expected energy savings by $99,121 annually, resulting in an additional $1,001,848 in positive cash flow over 10 years.
Project Partners:
- Installation Partner: Stones River Electric
- Lighting Supplier: Accendo Lighting
Project Management & Quality Assurance
A structured communication and reporting framework was integral to project success. Weekly status reports provided Arconic with updates on project progress, scheduling, and completion percentages.
Measurement & Verification (M&V) was conducted under Option A methodology, ensuring accountability in energy savings. The verification process included:
- Sampling of primary fixtures with pre- and post-installation wattage measurements
- Guaranteed light levels, with pre- and post-installation measurements to ensure compliance with project specifications
Through meticulous planning, collaboration, and execution, Woodstone Energy successfully delivered a high-impact energy efficiency project, providing Arconic with substantial cost savings, improved lighting performance, and long-term sustainability benefits.
