Ashland Foundry Installs Intelligent LED Lighting System from Digital Lumens at Manufacturing Facility

Digital Lumens of Boston, Massachusetts USA, announced that Ashland Foundry & Machine Works, Inc. in Ashland, Pennsylvania has upgraded the lighting in its 215,000-square-foot manufacturing facility to the Digital Lumens Intelligent LED Lighting System.

Ashland Facility 1In addition to the LED lighting, the retrofit project uses Digital Lumens specialized controls to further improve efficiency. Digital Lumens’ LightRules® software allows the foundry to manage lighting settings and enables the scheduling and management of lighting to match shift work, downtime, and holidays without needing to access fixture-mounted DIP switches. According to Digital Lumens, the lighting system installation doubled light levels for enhanced visual comfort in the workplace. The system reportedly provided functional, high-quality light for employees handling large machinery.
Combined, the LED lighting and the controls dramatically improve the efficiency of the lighting in the challenging production environment, saving 85% of the electricity that the lighting previously used.

Ashland Foundry was spurred by the 2013 Pennsylvania Department of Environmental Protection policy to switch to more efficient lighting. The foundry replaced the 400-Watt and 1000-Watt metal halide fixtures throughout its facility with intelligent LED high bay fixtures. The project reduced the foundry’s electricity bill by $85,652 since the lighting system’s deployment.

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Ashland Foundry is a manufacturer of castings and machined products in over 50 different iron, steel, chrome, and high alloy metals ranging from 50 to 7,500 pounds.

Ashland collaborated with Smart Start Lighting, a provider of turnkey LED lighting solutions, to manage all aspects of the project. Smart Start Lighting recommended using LED lighting and controls from Digital Lumens. They also helped with the utility rebate application and performed the system installation. PPL Electric Utilities provided a $109,000 utility rebate for the project, reducing the payback period to less than two years.

“Due to the harsh conditions, lighting has always posed a challenge in this environment, requiring frequent maintenance and replacements, which took a toll on both our financial and personnel resources,” said Alden Roberts, Facilities Superintendent at Ashland Foundry. “Long after the installation, we are still amazed at the level of control and flexibility the Digital Lumens system gives us to improve operations within the foundry while simultaneously slashing our energy usage.”

“In designing a lighting solution for a busy space like Ashland Foundry, we focused on identifying a rugged lighting system that was more sophisticated than simple LEDs to maximize long-term savings,” said Colin Kelly, CEO of Smart Start Lighting. “Understanding the unique challenges of illuminating foundries and machine shops, we knew that the solution for Ashland Foundry would need to be durable enough to withstand harsh conditions, powerful enough to provide high light levels for workspaces, and versatile enough to simply augment lighting settings anytime, anywhere. With these goals, the Digital Lumens system was clearly the right solution.”

“We are delighted that Ashland Foundry selected and deployed our system,” said Scott McClintock, Digital Lumens Vice President of North American Sales. “They join the growing list of heavy industrial customers adopting intelligent LED solutions for high-quality light, complete control, and savings in challenging settings.”