Project Profile

The Staples Distribution Center in Monroe,New Jersey is a 204,000 square foot shipping facility that supplies product for customers in New Jersey and Eastern Pennsylvania. The facility operates 24 hours per day Monday through Friday. There are over 100 employees that cover all three shifts.

Staples lighting retrofit program’s objectives were to increase the uniformity and quality of light throughout the warehouse, reduce energy usage, and maintain system reliability. During the planning stages for this facility, both conventional metal halide and fluorescent lighting systemswere designed. Staples had previously used a combination of metal halide and high pressure sodium luminaries but opted to test luminaries using T5 fluorescent lamps as an energy-effective alternative. T5 lamps were selected for their energy efficiency, long lamp life, easy switching, high lumen maintenance and even light distribution characteristics. Occupancy sensors are also being used in the narrow storage isles to switch off 80% of the lighting when the isle is not in use. GreenTech Energy Services design team calculated that the higher initial costs would be offset by substantial energy savings. The T5 project had a 2.1 year payback as compared to the metal halide alternative which had a 2.9 year payback. In addition, the electric utility provided a rebate as part of its energy incentive program. Overall, the T-5 fluorescent lighting system results in significant lighting energy savings compared to Staples’ conventional metal halide system designed to the same illumination criteria.

Employee response to the T5 lighting has been positive, with most responding that the lighting is more even and more comfortable than the old lighting system. “The new lighting has improved the overall environment in which our associates work in. It sends a clear message to all team members that we are committed to investing in technology to improve both our work environment and bottom line.”

• Reduce energy.
• Reduce life-cycle cost.The T5 product reduces the maintained cost of lighting compared to Staples’ conventional lighting systems.
• Meet average illuminance criteria using energy efficient products. Increase foot-candles.
• Minimize flicker utilizing high-frequency electronic ballast.
• Create pleasant work environment with design spaces that appear bright and inviting to employees. Reduce glare.The T5 product significantly decreases levels of visual disability and discomfort when compared to metal halide technology.
• Qualify for utility rebate.

• Reduce energy use in unoccupied aisles using occupancy sensors to switch lighting according to use.
• Reduce restrike time.T5 fluorescents can be switched on and off without a restrike delay.
• Provide uniformity.The T5 4 lamp system offers multiple lamps on shelving providing lighting overlap so that when a lamp burns out, work can continue until relamping is performed.

Economic Analysis

By using energy saving electronic ballast and T5 lamps as a building standard and reducing lighting use with occupancysensors, this Staples Distribution Center achieved a reduction of 60% in KWH usage for lighting, while maintaining or increasing light levels.