Pet Food Manufacturer Sees Two-Year Payback on LED Fixtures

3 Jan

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The Challenge

Diamond Pet Foods, a leading manufacturer of super premium, nutritious and natural pet foods, is a family-owned business with more than 40 years history of providing the highest-quality pet foods at an affordable price for dogs and cats of all ages. Thanks to its rigorous 151 ingredient checks and product quality system, the brand has become the choice of top breeders, kennel owners and families worldwide.

Planning to construct a new manufacturing facility, the Missouri-based company had been so impressed with the work ethic of employees at its Lathrop, California plant that it chose neighboring Ripon, California for the new site, just 30 miles away. The 300,000 square foot plant would be a Class II Div 2 facility as dictated by its raw materials, which arrive in powder form and are extruded into a pellet, then dried through an oven. Aiming to minimize energy consumption and achieve more sustainable operations at the new facility, the company installed solar panels designed to provide roughly one-quarter of the electricity to power the building.

The manufacturing environment posed a number of lighting challenges. First, the company needed an ultra-energy efficient system to reduce consumption and fully leverage the benefits of its solar system. Second, they required Class II Div 2 certified fixtures that would offer safety and reliability amid the high-vibration and dusty conditions. Ambient heat and humidity was also an issue, driving a need for lighting that would safely withstand up to 120°F and high humidity in the extrusion areas. With many hard-to-reach and low-clearance areas near process equipment, Diamond also needed dependable fixtures that offer longevity, low maintenance and ease of installation.

The Solution

All things considered, LED lighting was the natural choice. Diamond began with a trail of 16 Dialight DuroSite High Bay LEDs in the receiving area, prior to the facility coming online. Satisfied with what they saw, the company gave the green light to outfit the entire facility, including 304 2-foot and 4-foot Linear fixtures, 145 LED High Bays and 89 LED Area Lights, for a total of 538 Dialight LED fixtures.

The Result

The low profile of the Dialight LED fixtures enabled mounting in areas that would have been difficult with other bulky conventional lighting fixtures, and the company can expect to use at least 50% less energy compared to other options. Not only did the Dialight products off the rugged durability Diamond required, but each fixture is also backed by Dialight’s 5 year full performance warranty. Based on performance history, Diamond will likely enjoy up to a decade of reliable illumination, for a truly maintenance-free solution that adds to the significant energy savings. As a result of the energy and maintenance savings, the company easily hit its goal of less than two year pay back.

Employees immediately recognized the difference in the crisp, white, glare-free light at the Ripon facility compared to other plants that do not yet use LED. In fact, the project at Ripon has been such a success. Diamond is considering an LED retrofit at its Lathrop plant just up the road. Employees noted a significant difference in the bright white exterior lighting at the Diamond Pet Foods plant compared to the orange glow of the high-pressure sodium fixtures at the power generation facility next door.

Contact your CBT lighting specialist today for more information about Dialight’s high-efficiency LED high bay fixtures for industrial and commercial applications.

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