The new 300,000 sq ft Diamond Pet Foods facility in Ripon, CA went online in May 2012 with more than 500 high efficiency, Class II Div 2 LED fixtures by Dialight, provider of industrial and hazardous location LED lighting. Through combined energy and maintenance savings, the company expects a full return on its investment in less than two years while benefiting from improved visibility thanks to the clear, white light of the LEDs.
Addressing the Challenge
A manufacturer of super premium, nutritious, and natural pet foods, Diamond 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 Checks ingredient and product quality system, the brand has become popular with top breeders, kennel owners, and families worldwide.
When the time came to plan for a new manufacturing facility, the Missouri-based company was so impressed with the work ethic of employees at its Lathrop, CA plant it chose neighboring Ripon, CA for the new site. The 300,000 sq ft plant would be a Class II Div 2 facility as dictated by its raw materials, which arrive in powder form, are extruded into a pellet, and 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 1/4 of the electricity to power the building.
Lighting was more of an issue. 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.
LEDs the Best Solution
All things considered, LED lighting was the natural choice. Diamond consulted with Nelson & Sons Electrical, the company’s electrical service partner for more than 15 years and a specialist in lighting and electrical needs for the food processing industry, to help specify the best solution.
Diamond began with a trial 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-ft and 4-ft LED Linear fixtures, 145 LED High Bays and 89 LED Area Lights, for a total of 538 Dialight LED fixtures.
A Bright 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 offer 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 2-year payback. 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.
