Loc Performance – Lapeer, Michigan

Precision lighting retrofit delivers 64% ROI and major energy reduction in three days.

Energy Design Engineers modernized lighting at Loc Performance with an engineered LED retrofit that improved visibility, cut energy use, and delivered a rapid verified payback.

Manufacturing facility
64% ROI (sixty four percent return on investment)
3 days on site (three days on site)

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Project snapshot

ROI
64% ROI (sixty four percent return on investment)
Utility incentive
33% (thirty three percent) of project cost covered
Fixtures removed
61 fixtures (sixty one fixtures) removed through optimized design
Energy reduction
349,925 kWh (three hundred forty nine thousand nine hundred twenty five kilowatt hours) saved per year
Payback period
Under 2 years (less than two years)
Installation time
3 days (three days) for interior and exterior

Project highlights

Key metrics at a glance

ROI
64% ROI (sixty four percent return on investment)
Utility incentive
33% (thirty three percent) of the total project cost is covered by incentives
Fixtures removed
61 fixtures (sixty one fixtures) eliminated through optimized layout and design
Lighting energy reduction
349,925 kWh (three hundred forty nine thousand nine hundred twenty five kilowatt hours) saved annually
Payback period
Less than 2 years (less than two years)
Installation time
3 days (three days) including interior and exterior work
Average light levels
From 21 fc to 48 fc (from twenty one footcandles to forty eight footcandles)
with a 129% increase (one hundred twenty nine percent increase)
Lighting load vs. total energy use
Reduced from 20% (twenty percent) of total energy use to 5% (five percent)

Outdated lighting increased cost and reduced visibility

The Loc Performance facility in Lapeer was operating with older, inefficient lighting that created uneven illumination across the plant. Dark zones on the shop floor and at exterior areas reduced visibility and impacted safety.

The lighting system consumed a large share of the plant energy load and required frequent maintenance and relamping. This combination of high energy use and recurring service calls added cost and risk to daily operations.

Loc Performance needed a lighting upgrade that could improve light quality, lower energy use, and be installed quickly so that production would not be disrupted.

Solution

High efficiency LED retrofit optimized for performance

Energy Design Engineers designed and implemented a precision LED retrofit tailored to the way the plant operates. The work focused on uniform illumination and long term reliability while reducing the total number of fixtures.

Key solution elements

• Optimized fixture layout that removed
  61 fixtures (sixty one fixtures)
  while increasing light levels across work areas.
• Integrated interior and exterior upgrade completed in
  3 days (three days)
  to keep production on schedule.
• Utility incentive coordination that covered
  33% (thirty three percent)
  of the total project cost.

The project was delivered as a coordinated effort, from audit and design through installation and close out, giving Loc Performance a single point of responsibility and a clear performance baseline.

Higher light levels and lower cost in a matter of days

The retrofit produced immediate measurable gains in energy performance and visual quality across the facility.

Financial
64% ROI (sixty four percent ROI)

The project delivers a 64% return on investment with a payback period of less than 2 years (less than two years), supported by strong incentives and ongoing energy savings.

Energy impact
349,925 kWh (three hundred forty nine thousand nine hundred twenty five kilowatt hours) saved per year

Lighting energy use dropped sharply with annual savings of 349,925 kWh. The share of total facility energy used for lighting moved from 20% (twenty percent) down to 5% (five percent).

Light levels
21 fc to 48 fc (twenty one to forty eight footcandles)

Average light levels increased from 21 footcandles to 48 footcandles, which represents a 129% increase (one hundred twenty nine percent increase) and removes shadows across production and circulation areas.

Operations
61 fixtures removed (sixty one fixtures removed)

A more efficient layout reduced fixture count while improving coverage. Fewer fixtures and modern drivers lower maintenance needs and simplify future service.

Safer, brighter, and more efficient facility

With higher average light levels and more consistent coverage, Loc Performance now has a safer and more comfortable environment for employees. Operators and maintenance staff can see clearly in former shadowed areas which supports quality control and reduces risk.

The reduction in energy use and fixture count helps lower operating costs year after year, while the simplified lighting layout makes ongoing maintenance easier to plan and complete.

Why it matters

Engineering, not just replacement

This project shows how targeted engineering and thoughtful design, not just one for one fixture replacement, can deliver strong financial performance together with better visibility and safety.

The approach used at Loc Performance can be applied to other manufacturing facilities that want clear measurable results from a focused lighting upgrade.

Summary

Simple summary by category

Financial
64% ROI (sixty four percent return on investment) with payback in less than 2 years (less than two years), supported by 33% (thirty three percent) utility cost coverage.
Operational
61 fixtures (sixty one fixtures) removed while improving coverage, and the full interior and exterior upgrade completed in 3 days (three days).
Energy
349,925 kWh (three hundred forty nine thousand nine hundred twenty five kilowatt hours) saved annually and the lighting share of total energy use reduced from 20% (twenty percent) to 5% (five percent).
Human impact
Brighter, more uniform light that improves visibility, supports safer work, and raises comfort for employees across the facility.

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