Oliver Fiberglass

Commercial

Oliver Fiberglass

Helios Energy™ partnered with Toyota Material Handling Mid-South to execute a total LED retrofit project in Oliver Fiberglass’ 330,000 square foot manufacturing facility.

Challenge

Create a lighting solution that would substantially improve the quality and amount of lighting in the facility, thereby improving safety of all employees and quality control capacity. Replace three generations of ceiling light fixtures throughout a facility originally built in 1947 and bring all underlying electrical work up to current standards for LED fixture implementation. 

Need 1: Replace all existing fixtures, which included multiple generations of technology, with fewer high-efficiency LEDs.

Need 2: Perform a substantial scope of electrical work to bring antiquated back-end systems up to new technology standards.

Need 3: Upgrade the quality of light to meet appropriate photometric requirements across areas of the facility where Oliver Fiberglass will be installing new racking systems in the future.

Need 4: Produce a system that realizes energy utilization and cost savings.

Need 5: Deliver on all project expectations in a bustling fiberglass manufacturing facility that had inventory, equipment, and schedules that needed to be worked around to execute.

Oliver Fiberglass

Solution

Prior to partnering with Helios, the facility had 1,912 high bay fixtures on site with multiple generations stacked on top of one another. Further, over half of the existing fixtures were rated as non-functional.  To optimize performance and efficiency, the Helios Team solutioned a means to remove and cap off 1,162 of the original fixtures and replace them with 750 240-Watt, 190 Lumen Per Watt (LPW) High Efficiency fixtures with Integral Motion controls.  The controls solution lowered light output in specified areas of the plant, offering the flexibility to bring illuminance to full capacity if the need arises, and established a higher density of fixtures in areas of the production plant that require higher foot candle readings (200 fc).  Each of the 750 new fixtures delivers 45,600 Lumens, allowing the Helios Team to design a new lighting layout that doubled lighting performance and delivered a simple payback for Oliver of 1.9 years.

Average Foot Candles Before: 40 FC
Average Foot Candles After: 80 FC

Oliver Fiberglass
Details Table

The Helios Energy™ Impact

Substantial increase in quality of the fiberglass product along with the morale of all employees due to improved safety and ability to see all work being done.

About Our Client

Oliver Fiberglass Products (OFP), headquartered in Hohenwald, Tennessee, is a major manufacturer of fiberglass since 1995. OFP has been manufacturing walk-in bathtubs, showers and travel trailers. OFP’s major considerations of manufacturing fiberglass is their Quality Assurance Program. With over 150 employees, OFP provides skilled technicians, professional sales and design staff. We market our products all over the United States and Canada. We utilize a network of distributors and independent representatives.

 

About Our Partner

Toyota Material Handling Midsouth is a locally-operated material handling equipment and warehouse solutions provider servicing manufacturers, distributors, and businesses of all sizes across the Midsouth. From new equipment and used, to rental, service, parts and more, Toyota Material Handling Midsouth is a full-service partner you can trust. TMH Midsouth delivers world class material handling solutions that reduce costs, maximize productivity, and increase safety. They service all makes and models of equipment so whether you’re operating a Toyota or not, they can get the job done. Toyota Material Handling Midsouth doesn’t just sell and service forklifts, they help businesses solve problems. From the equipment in your fleet to the operations of your warehouse, their team creates solutions that make your business more profitable. Toyota Material Handling Midsouth is backed by the world’s largest material handling solutions provider, Toyota Material Handling, U.S.A., Inc, manufacturer of the world’s top selling and highest quality forklift.

 

Testimonials

"We love the lights and the lighting controls. We have seen a significant increase in product quality and employee moral as a result of the lighting project."

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