CUSANOS BAKERY CASE STUDY · 2018-12-19 · Cusanos Bakery Case Study For the loading and unloading...

“It was great working with the people at

Xeleum...and our ability to better showcase

this new state-of-the-art operation is a

great business benefit for us.”

Michael Greco, Co-OwnerCusanos Bakery

While its multiple facilities in Hallandale Florida had served it well over the years as Cusanos Bakery grew into a major supplier of commercial bakery products in Southern Florida and throughout the United States, its strong and ongoing growth dictated a move to a much larger and technically advanced operation capable of far greater daily output.

The current owners, Michael, Salvatore, and Santo Greco, fifth generation bakers that carry on the family’s 100 year old tradition of baking quality bread products, selected a 260,000 square foot facility in Coconut Creek, Florida as the location for their new state-of-the-art facility and, for the indoor and outdoor lighting at this new location, they selected Xeleum Lighting.

CUSANOS BAKERYCASE STUDY

Xeleum LED Lighting Selected by Cusanos Bakery for its New State-of-the-Art Manufacturing Operation

Xeleum Lighting, LLC. 3430 Quantum Blvd. Boynton Beach, FL 33426Phone (954) 617-8170 • Fax (561) 557-3925 • www.xeleum.com

Copyright © 2015 Xeleum Lighting, LLC. All Rights Reserved. For informational purposes only. Specifications subject to change without notice.

Xeleum and the Xeleum logo are registered trademarks. All other trademarks are the property of their respective owners.

CHALLENGE: Meeting the changing demandAmong the challenges presented by this new facility was the need to replace virtually all of its existing lighting which, while suitable for its prior owner’s use as illumination for a low occupancy furniture warehouse, hardly suited the needs of a production facility that requires high quality lighting for the operation of a high tech, high volume commercial bakery.

Case StudyCusanos Bakery

LIGHTING SOLUTION: A depth of technical capability and product offeringXeleum’s first order of business was to perform an engineering lighting study of the various locations in order to determine the fixture types and quantities best suited to provide the desired illumination at each of the various working surfaces within the facility. The results of the study was that five different Xeleum fixture types, as summarized in the below table, would be employed.

In addition to the 260,000 square foot former warehouse space being converted to the Cusanos Bakery production facility, the site also included a semi-detached 140,000 AAA front office section which building owner Fields Realty retained for use as multi-tenant office suites. For the lighting in the office suite common areas, the Xeleum Titanium Series troffers were used because of their superior photometric characteristics.

SUMMARY OF PRODUCTS INSTALLED: Total 805 Xeleum fixtures and controls were installed

TYPE QTY FIXTURE

Parking Area 1000 W Metal Halide 180 W Zephyr Shoebox 26

Main Baking Area 400 W Metal Halide 200 W Hercules 90

Stairwells 4 Foot 2 Lamp T8 fixture Athena with RF wireless controls 6

Cusanos Offices 3 Lamp Fluorescent fixture2x2 Cobalt2x4 CobaltXCO-200 controls

2213625

Processing Rooms 400 W Metal Halide100 W Cronus

120 W Cronus

186

Freezers 400 W Metal Halide 150 W Cronus 34

Test Kitchen Warehouse 2 Lamp 8 Foot T12 fixtures 100 W Hercules 29

Loading Unloading Area 2 Lamp 8 Foot T12 fixtures Artemis Fixtures with RF wireless controls 218

Front Office Suites 2 Lamp 8 Foot T12 fixtures Titanium Troffers 195

LOCATION ORIGINAL FIXTURES XELEUM LED REPLACEMENT FIXTURES




Electric Cost $158,000

Maintenance $12,075

HVAC $14,000

Total Annual Savings $184,075

ANNUAL SAVINGS

For the stairwells, the Xeleum Athena Stairwell fixtures were used. They provide additional savings of electric energy cost because they are fully illuminated only when there is occupancy in the stairwell and, at all other times, the illumination is reduced by more than 80%.

For the Main Baking and Test Kitchen Warehouse areas, a combination of 100 watt and 200 watt Xeleum Hercules LED fixtures were used because these rugged and durable luminaires are ideally suited for the high ceiling (42 feet) and wide area working surfaces characterized by these locations.

For the outdoor parking areas Xeleum 180 watt Zephyr fixtures were used because this IP65 rated shoe box fixture is specifically designed for illumination of these types of large outdoor spaces.


“Not only is there a great improvement in overall illumination, but this new LED technology has made possible

a very substantial savings for us in electric energy cost.”

Santos Greco, Co-OwnerCusanos Bakery


For the loading and unloading areas the Xeleum Artemis fixtures were used. In addition to providing excellent illumination, they provide additional savings of electric energy cost because they are fully illuminated only when the loading and unloading docks are being used and, at all other time, the illumination can be reduced to either 50%, 10% or fully OFF. For the freezer, the Xeleum 150 watt Cronus was used because it operates comfortable even at freezing temperatures while providing excellent wide area lighting.

For office locations, the Xeleum Cobalt fixtures, together with Xeleum XCO-200 control system, were used. In addition to the excellent illumination provided by the Cobalt troffers, the daylight harvesting and occupancy sensing features of the XCO-200 control systems provide additional electric cost savings.

For more information on how Xeleum LED lighting can reduce electric energy cost and improve illumination at your existing or new facility, please contact us at [email protected], or call us at: 954-617-8170. Visit us at www.xeleum.com.

END RESULT: Superior Lighting and Substantial savings in electric energy cost

Jon Cooper, COO of Xeleum Lighting stated…”We are thrilled that Cusanos Bakery selected Xeleum to supply the lighting for its new 260,000 square foot facility in Coconut Creek, Florida and it was terrific working with the Grecos’ on this project.” He added, “Being able to perform a lighting study on this large facility, along with the opportunity of specifying and installing five of our LED fixture types was a wonderful chance for Xeleum to demonstrate the depth of its technical capability and product offering.”

Michael Greco, co-owner of Cusanos Bakery stated…”It was great working with the people at Xeleum Lighting and the new LED fixtures they installed are providing a very high quality of lighting at all locations within our facility.” He added, “We expect that productivity will increase and, for both customers and visitors who tour the new location, our ability to better showcase this new state-of-the-art operation is a great business benefit for us”.

Michael Greco, stated, “Not only is there a great improvement in overall illumination, but this new LED technology has made possible a very substantial savings for us in electric energy cost. He added, “The annual cost savings of $184,075 will pay for the 805 fixtures and controls that were installed in less than 30 months and, thereafter, Cusanos Bakers will have the full benefit of this cost savings. In addition, as a result of this conversion, CO2 emission was reduced by 1,000 pounds.”

Steve Fields, building owner, stated, “Conversion to LED lighting was a great upgrade for the building and we find the quality of this new lighting to be far superior to that which was replaced.” He added, “We appreciate the cost saving that will result from both the reduced energy usage and from not having to replace burned out fixtures on a regular basis, as was necessary with the prior lighting.”




CUSANOS BAKERY CASE STUDY · 2018-12-19 · Cusanos Bakery Case Study For the loading and unloading...

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