For more than 30 years, Rockline Industries has built a reputation as a trusted supplier of household paper and non-woven products. As part of the Arkansas-based company’s efforts to increase use of sustainable supplies and improving the environmental friendliness of its products, Rockline officials have begun working to improve its facilities and operational practices to reduce its carbon footprint and environmental impact.

As part of its program, the company recently replaced its inefficient metal halide fixtures with Dialight’s high-efficiency DuroSite LED High Bay luminaires inside its production facility.
 
Before installing energy-efficient LED lights, Rockline’s energy consumption for lighting was excessive. The company had 15 metal halide fixtures burning 12 hours a day, five days a week in the mixing room, and another 125 ablaze 24/7 in the manufacturing area at its Booneville, AR baby wipes production facility.
 
To improve energy efficiency and reduce total operating costs, the company recently replaced all 140 of the 400W metal halide fixtures in both areas with Dialight’s high-efficiency DuroSite LED High Bay fixtures. The new fixtures slashed future energy consumption per fixture from approximately 400W to just 150W per unit. They LED lights also improved light performance and output, reduced maintenance costs and qualified Rockline a substantial rebate for its energy efficient practices.
 
“The installation went very smoothly with minimal interruption to our manufacturing process,” said Nick Santoleri,Vice President of Manufacturing at Rockline. “The beauty of it is that the new fixtures use all standard plugs, so there was no need for re-wiring during the retrofit.”
 
In addition to the significant energy savings, the new LED fixtures have also helped reduce lighting maintenance. When you factor in the cost of renting a lift to reach the 18’ mounting height, maintaining the old fixtures was a large expense every year.
 
The Dialight DuroSite Series LED High Bay fixtures combine the latest Cree® XLamp® XP-G LED, precision optics and next generation thermal management practices. The long-life performance of the new Dialight LED fixtures means that Rockline can now expect to get as much as 10 years of life out of each fixture ‑ with the first five covered by Dialight’s no-cost replacement warranty.
 
The company and its employees are both pleased with the significant temperature drop inside the manufacturing facility as a result of the new LED fixtures.
 
“Employees have noticed that it is cooler, and they like the light produced by the LEDs better than the old lights,” Santoleri said. “It’s not only more uniform, but the crisp white light is easier on the eyes.”
 
As a result of its energy-saving initiatives, which included the Dialight DuroSite retrofit, Rockline is qualified and has already applied for a substantial $48,000 energy-savings rebate through American Electric Power’s Southwestern Electric Power Company.
 
“The energy and cost savings combined with the opportunity to receive the energy efficiency rebates has made the conversion to LED lighting a substantial part of our sustainability efforts,” Santoleri said. “We’re already looking to convert other areas where safety and color rendering are just as important as energy efficiency, including our building exterior and truck loading area.”
 
 Facts about the Installation: 

• 140 metal halide lights each consuming 400 Watts were replaced with 140 DuroSite LED High Bay fixtures from Dialight, which only consume 150 watts.

• Without the excess heat generated from the metal halide fixtures, Rockline’s HVAC engineers have noted a 20-ton (10 to 15 percent) reduction in air conditioning demand to maintain comfortable temperatures inside the facility - an additional energy saving and sustainability benefit for the company.