Charlotte LED Pros successfully partnered with Martin Sprocket & Gear to execute a comprehensive LED lighting upgrade across their Charlotte facility. The project replaced 187 fixtures throughout warehouse, office, and exterior spaces, achieving a 60% reduction in lighting energy consumption. With Duke Energy Smart $aver® rebates covering 50% of project costs, Martin Sprocket & Gear achieved full payback in just 15 months while creating a brighter, safer work environment for their employees.

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Martin Sprocket & Gear

Martin Sprocket & Gear stands as a leading manufacturer of power transmission and material handling products, serving industrial markets across North America. Their Charlotte facility operates as a critical distribution and manufacturing hub, running multiple shifts to meet customer demands. With rising energy costs impacting operational margins and aging lighting infrastructure requiring constant maintenance, Martin Sprocket & Gear sought a partner to modernize their facility lighting while maintaining uninterrupted production schedules.

The Challenge

Martin Sprocket & Gear faced several operational and financial challenges with their existing lighting system:

1. Excessive Energy Costs

• Outdated metal halide high-bays in warehouse consuming 400W per fixture
• T12 fluorescent fixtures in offices nearing end of life
• Exterior HPS fixtures running all night at high wattage
• Annual lighting costs exceeding budget allocations

2. Maintenance Burden

• Frequent high-bay lamp failures requiring lift rental
• Production disruption for warehouse lighting repairs
• Safety concerns when changing fixtures at 30+ foot heights
• Stockpiling expensive replacement bulbs

3. Inadequate Light Quality

• Dim conditions in picking/packing areas affecting accuracy
• Long warm-up times for metal halide fixtures after power events
• Poor color rendering making part identification difficult
• Inconsistent lighting levels across work zones

4. Safety and Compliance

• Below-OSHA recommended foot-candles in work areas
• Dark spots in exterior loading areas creating hazards
• Emergency lighting reliability concerns
• Insurance recommendations for improved facility lighting

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Charlotte LED Pros developed a strategic approach to transform Martin Sprocket & Gear's lighting infrastructure while maximizing available utility incentives and minimizing operational disruption.

Technology Deployed

Warehouse Areas (125 fixtures)

• High-Bay LED Fixtures: 150W LED replacing 400W metal halide
• Features: 20,000+ lumens, 5000K color temperature, instant-on capability
• Controls: Motion sensors in low-traffic aisles for additional savings

Office Spaces (42 fixtures)

• LED Panel Troffers: 40W LED panels replacing 128W T12 fluorescents
• Features: 4000K color temperature, 90+ CRI, dimmable capability
• Benefits: Reduced eye strain, improved worker comfort

Exterior Areas (20 fixtures)

• LED Wall Packs & Flood Lights: 80W LED replacing 250W HPS
• Features: Photocell and timer controls, dark sky compliant
• Security: Enhanced visibility for loading docks and parking areas

Smart Controls Integration

• Occupancy sensors in warehouse aisles (30% additional savings)
• Daylight harvesting near dock doors and skylights
• Programmable scheduling for office and exterior zones
• Emergency lighting test features built into fixtures

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This case study represents actual project results. Individual savings may vary based on facility characteristics, existing infrastructure, and usage patterns. All figures are based on measured performance data and utility billing records.