PepsiCo Case Study (Food & Beverage)

Case Study: PepsiCo


Dialight Reduces PepsiCo’s Energy Consumption & Costs

PepsiCo is an American multinational food, snack, and beverage corporation with an annual revenue exceeding $64 billion across more than 200 countries and territories, making it the second largest food and beverage business in the world.

In 2016, PepsiCo announced an ambitious global sustainability agenda designed to foster continued business growth in a way that responds to changing consumer and societal needs, as well as reducing its environmental footprint through operational efficiencies and mobilisation of its suppliers and business partners.

The Situation

As a dedicated Green Mark certified facility, PepsiCo’s manufacturing plant in Singapore was continuously seeking to improve energy efficiency.

The facility historically used a combination of antiquated 250w and 400w hazardous and non-hazardous metal halide luminaires with certain areas continuously operating at 100% light output, even during non-operational hours.

In 2017, PepsiCo commissioned an energy review of their Singapore manufacturing facility, the results of which identified converting to an LED lighting system one of their top priorities.

The main motivation for the review was to reduce the plant’s overall energy consumption, thereby lowering carbon emissions and operating costs.

The Solution

In In 2017, Dialight presented PepsiCo with a comprehensive lighting design solution that would maximise the company’s return on investment and significantly reduce the company’s energy costs.

“We wanted a solution with fully controllable, programmable LED lights that offered scheduling flexibilities,” Ahmed Usman, PepsiCo Engineering Manager said.

Dialight replaced over 140 metal halide High Bay fixtures with a combination of Vigilant™ 18,000 lumen and Vigilant™ and SafeSite™ 14,000 lumen LED High Bays, along with five associated occupancy sensors to deliver an intelligent LED lighting system that can be controlled via Wi-Fi with a personalised URL.

Dialight was able to deliver a fast turnaround on this project so PepsiCo’s was able to start seeing energy benefits sooner.

The Result

Drawing on their extensive range of products, Dialight dramatically improved PepsiCo’s energy utilization with Vigilant™ and SafeSite™ High Bay range of LED fixtures and the company’s IntelliLED™ controls system.

The IntelliLED system now enables Pepsi to schedule lights based on the operational hours and also dim-down or power up lights based on the operational requirement, saving the company on maintenance costs and reducing energy consumption.

The scheduling feature gives PepsiCo the option to dim lights down to 10% or switch the system off completely during non-operation hours.

The new LED lighting provides such an improvement in visual clarity that the company chooses to keep their luminaires dimmed to 50% output, to further benefit from the energy saving, while still achieving better results than the outdated metal halides.

“We have seen a significant reduction in energy consumption as well as in maintenance costs,” Usman said.

“Dialight’s LED solution gives us with flexibility with lighting schedules and future integration of lights into our digital platforms, while Dialight’s 10-year warranty also gives us confidence in the reliability of the products moving forward.”

Installation Snapshot

  • Food and beverage manufacturing plant in Singapore
  • Metal halides operated at 100% light-output, even during non-operational hours
  • Replaced over 140 metal halide fixtures with a combination of Dialight Vigilant™ 18,000 lumen Vigilant™, SafeSite™ 14,000 lumen LED High Bays, 5 associated occupancy sensors, IntelliLED™ controls system
  • Dramatic improvement in visibility, energy consumption, and maintenance costs

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