Bar Processing – Monroe, Michigan

 Download Bar Processing Case Study

Case Study-BarProcessing_v1_2 Case Study-BarProcessing_v1

Bar Processing Before Lighting Upgrade

Bar Processing in Monroe, Michigan was looking for a better option for lighting. Their current 400 watt metal halides  did not produce the needed light levels.

And, like many manufacturing facilities, they opened their delivery doors to get as much additional light into the facility  as possible. Leaving the delivery doors open was fine in the summer but it was no help during the winter and the night  shift. To the left, you can see the plant with the delivery door open. The majority of the light is being produced from the open door

Bar Processing looked at several vendors to do their lighting project and decided GUSCO was the perfect partner.  GUSCO had a unique lighting design using a combination of Lusio 6M and 4M fixtures.  In the next image, you can see the plant after 24 – 6M Lusio’s were installed in the center of the plant and 24 – 4M lusio’s were installed on the outside rows, and the doors were closed.

Bar Processing after Installation of Lusio 4M and 6M LED High Bays

By implementing the solution, Bar Processing was able to reduce their current annual operational savings by $8,100, and the project paid for itself in a little over four years. But, the best part was the feedback from the employees in the plant. The employees said the new lighting was making a big impact in their work environment.



Screen shot 2014-11-13 at 4.46.03 AMCase Study-BarProcessing_v1_5


To the left, you can see the photometric design GUSCO did for the plant. The majority of the work is done in the center so we did two rows of the higher light output Lusio 6M’s. For the two outside rows, we used two rows of Lusio 4M’s. The center work area now has on average 43 foot candles the sides average 26 foot candles. Before the LED lighting upgrade the plant had an average of 10 to 15 foot candles. Now the customer has more than double the amount of light while using 35% less energy.