Investing in the Facility. Not the Utility. Steelscape`s Lighting Retrofit.

CASE STUDY
Investing in the Facility. Not the Utility.
Steelscape’s Lighting Retrofit.
With the help of Ally Energy Solutions, Steelscape is
benefiting from a lighting strategy that redirects funds
budgeted for the utility to finance investment costs while
reducing consumption and furthering the company’s commitment to
environmental responsibility.
Steelscape is a leader on both ends of the sustainability spectrum.
The national steel manufacturing company incorporates eco-friendly philosophies into virtually every
aspect of its operations, right down to the metallic-coated and pre-painted steel it produces.
At Steelscape’s two locations – one in Kalama, Washington, and another in Rancho Cucamonga,
California – the company manufactures products that help builders realize many of the design
elements necessary for reducing energy demand in commercial facilities. For example, many of
Steelscape’s coatings meet ENERGY STAR requirements and are certified with the Cool Roof Rating
Council. Steelscape also offers material made using recycled content in quantities that meet the U.S.
Green Building Council LEED 2009 requirements.
Steelscape also fosters a workplace culture built on the highest standards of safety and environmental
stewardship. In fact, its California plant is currently installing an impressive solar array, harnessing
renewable energy from the sun to power a portion of its manufacturing operations.
When the company decided to further reinforce its sustainability strategy and improve the lighting of
its facility in Washington, it turned to Ally Energy Solutions for an audit, design, and turnkey
implementation. After assessing Steelscape’s current state of operations, energy experts executed a
plan to leverage utility rebate opportunities to cover nearly half of the implementation cost while
generating an estimated annual savings of $70,000 and a reduction in CO2 emissions of more than
1.5 million pounds.
The Company
Steelscape’s Washington plant has several distinct work areas that are each responsible for a specific
process in the product development cycle of metallic-coated and pre-painted steel.
Hot band coils enter the facility through the pickling line, where they are uncoiled and cleaned with a
series of acid baths to ensure a proper surface for galvanizing. They are then side-trimmed to the
customer’s width specifications, recoiled, and sent to the cold rolling mill, where the thickness is
reduced according to requirements.
From there, the metallic coating line coats the steel substrates with a protective combination of
metals to provide effective corrosion resistance. Depending on the order, substrates then follow one
of several paths. Certain pieces are sent directly to the export area and packaged for delivery, while
others are sent to the paint line to be pre-treated, primed, and painted and/or sent to the cut-tolength line to be cut to a desired length before being packaged for delivery in the export area.
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CASE STUDY
The Energy Opportunities
Prior to the retrofit, the plant used a combination of fluorescent and metal halide
fixtures and had no occupancy controls. Lighting maintenance was a bit of a
task, especially in areas of the facility with high ceilings, and the combination of
fixtures meant that crews were required to keep a wide range of parts on hand
for repairs when issues arose.
Pickling Line
Before and After
With these challenges in mind, the experts of Ally Energy Solutions designed
and implemented a plan customized to each work area using the same LED
fixture throughout the building but in different modular configurations based on
ceiling height.
The strategy — which gives Steelscape the advantage of providing workers
with improved lighting tailored to each functional area while streamlining
maintenance issues — focused on five areas.
Pickling Line
Before the retrofit, this portion of the facility was outfitted with fluorescent T8
fixtures, which hung 30 to 35 feet in the air and created a large amount of heat
buildup. The heat intensity, combined with steam from acid baths on the line,
created a significant risk of fixture corrosion. With the unique design of the AES
specified fixture that features a combination of sturdy “industrial grade” frame
and chassis separating the driver from the LED diodes, lighting-related heat
buildup is effectively managed, which, in turn, reduces the likelihood of modular
units deteriorating over time.
Metallic Coating Line
Metallic Coating Line
Before and After
The metallic coating line has a tower with ceilings roughly 90 feet high.
Historically, this created significant challenges for lighting and controls and
related maintenance.
To mitigate these issues, Ally Energy Solutions installed three-piece modular
fixtures to deliver an adequate level of brightness in the work space. Energy
experts also used wireless controls, which allow for greater flexibility in the
distance between sensors and fixtures. (Traditional controls are used in
environments with ceilings up to 50 feet high.)
While LEDs were used throughout the entire retrofit, the lifespan of these bulbs
is particularly noteworthy in this specific area of the facility. The metal halide
fixtures that were previously in use have a much shorter lifespan compared to
the modern technology available through LED lights.
Prior to the retrofit, bulbs were changed much more often – which, in an area
with 90-foot ceilings, translated to added safety risks for the maintenance team.
LEDs are designed to function much longer and have an estimated lifespan of
100,000 hours. With controls, these fixtures can last more than 10 years and
have the potential to dramatically reduce maintenance risks.
Paint Line
The paint line is among the hottest environments in the facility, in addition to the
pickling and metallic coating lines. Although LEDs reduce the heat buildup in the
room and deliver more accurate lighting to support quality in the production
process, the high temperatures of this area also pose a threat to the lifespan of
the fixture. To avoid burnouts, Ally Energy Solutions selected fixtures that better
manage temperatures and help block damage from hot environments.
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CASE STUDY
Cut-to-Length Line
Because the ceilings over the cut-to-length line are mid-height, Ally Energy
Solutions chose two-piece modular fixtures for this portion of the retrofit.
Roll Line
Before and After
It’s important to note that several cranes regularly move material in and out of
this area as part of day-to-day operations. This required careful consideration by
the team at Ally Energy Solutions when developing the installation plan.
To uphold safety standards and ensure minimal disruption to the facility’s
production schedule, platforms were constructed on top of the cranes to replace
the old metal halide fixtures with LED lighting.
Export
The existing metal halide fixtures were also replaced with LEDs in the export
area, and occupancy controls were installed to turn lights completely off when
the room is vacant.
The Results
Lighting costs for a manufacturer of this size may only account for 1 to 2 percent
of the total energy spend. But despite the small percentage, minor improvements can actually translate to significant annual savings – especially when nearly
half of the implementation cost is funded through utility rebates.
In the case of Steelscape, the project will ultimately save the company an
average of $70,000 per year, reduce annual energy consumption in lighting by
more than 1.2 million kWh, and decrease annual CO2 emissions by more than 1.5
million pounds.
Lighting
Before and After
The total investment cost to the manufacturer was just under $1 per square foot.
But because the project qualifies for $.40-.50 per square foot in utility rebates,
the net simple payback period is only 2.94 years. And the cash flow that will be
generated from the resulting cost-savings over the next 10 years will total nearly
$500,000.
Conclusion
This case study demonstrates how Ally Energy Solutions can leverage lucrative
utility rebates to justify implementation costs and create the business case
necessary to drive improvements in efficiency. It also underscores the team’s
blank-canvas approach to building the right strategy for the business and the
bottom line.
At Ally Energy Solutions, we are committed to helping clients invest in their
facilities – not their utilities.
Our energy experts sit on the client’s side of the table, operating as an
independent and trusted resource, with no affiliations to manufacturers or
product lines, to design and implement plans that maximize operational
functions and savings opportunities while reducing costs. We execute
engineering and design solutions according to specification, with minimal
disruptions to operations, on time, and at budget.
This broad base of capabilities and extensive knowledge makes Ally Energy
Solutions the better solution for precision in energy cost management and
efficiency.
For further information, visit www.ally-energy.com or call 844.AES.ALLY.
Ally Energy Solutions // allyenergy.com // 844.AES.ALLY
Ally Energy Solutions // allyenergy.com // 844.AES.ALLY