Lighting often goes unnoticed until it starts to limit productivity and comfort. For Acorn Recognition, a United States manufacturer of custom plaques and awards in Wilmington Delaware, aging fixtures were slowly making precise work harder and energy bills higher.
A LIBULBS LED lighting retrofit changed that. The production floor is now brighter, safer and more efficient, with energy savings that directly support the bottom line.
In this project story we will walk through what changed, how the lighting was designed and why this type of upgrade makes sense for small manufacturers that want better light and lower costs.
Who is Acorn Recognition
Acorn Recognition specializes in custom plaques, awards and recognition pieces for organizations that care about presentation and quality. Their work involves detailed engraving, careful finishing and precise assembly, all of which depend on clear, consistent lighting.
Facility address
Acorn Recognition
15 James CT
Wilmington DE 19801
Inside the building is a busy production floor with engraving equipment, workbenches, packing areas and storage racks. It is a classic small manufacturing environment where every square foot matters and visibility can influence both speed and accuracy.
The problem with the previous lighting
Before the upgrade Acorn Recognition relied on older lighting technology that had grown less effective over time. Light output had dropped, colors no longer looked clean and the system demanded constant attention from maintenance.
Typical issues included
- Uneven light levels with bright areas directly under fixtures and dim zones between them
- Shadows falling across work surfaces, especially at engraving tables
- Color that looked slightly off and made fine detail harder to inspect
- Frequent lamp and ballast failures that consumed maintenance time and budget
For employees this meant more eye strain and more effort to double check small text and intricate designs. For the business it meant higher electricity costs and ongoing maintenance simply to keep the existing system running.
Over time the team realized that better lighting would not only improve comfort, it would also support productivity, quality control and energy performance.
Project goals for the lighting upgrade
When Acorn Recognition began exploring a lighting retrofit, they set clear goals so the project would deliver real value rather than a simple one for one replacement.
- Improve visibility and comfort for detailed engraving and finishing tasks
- Create a safer, brighter production environment with consistent light levels
- Reduce energy consumption and electric utility costs
- Standardize lighting across the floor so every workstation feels the same
- Achieve a fast payback to support business and financial objectives
Why Acorn Recognition chose LIBULBS LED lighting
Many LED products exist, but Acorn Recognition needed a partner that understood the realities of a working factory, not just showroom conditions. LIBULBS LED lighting stood out for several reasons.
- Industrial and commercial LED fixtures designed for demanding environments
- Clear performance data on light output, efficiency and lifetime
- Practical mounting and spacing options that worked with the existing structure
- Support in reviewing layout concepts and estimating energy savings and payback
By choosing LIBULBS, the team gained a lighting partner focused on long term performance and reliability, not only first cost.
Designing the new lighting layout
The retrofit began with a careful assessment of the current installation and how the space is actually used each day.
During the site walk the project team
- Mapped existing fixture locations and mounting heights
- Identified areas where light levels were too low or too uneven
- Flagged critical work zones such as engraving stations and inspection areas
From this information a new layout was created using LIBULBS LED fixtures selected for
- Appropriate lumen output to bring light levels up to modern standards
- Optics that distribute light evenly across open floor and work surfaces
- A neutral color temperature that supports accurate reading of fine text and finishes
The objective was not simply to swap old fixtures for new ones, but to deliver a deliberate system that supports how Acorn Recognition operates today and in the future.
Installation with minimal disruption
Production could not simply stop during the project. To keep operations moving, the installation was planned and executed in phases.
- Sections of the floor were upgraded while other zones remained active
- Work was temporarily shifted as fixtures were removed and replaced
- Safety was maintained with clear temporary lighting and marked pathways
As each zone received the new LIBULBS fixtures, employees noticed an immediate difference. Work areas looked clearer and more defined even before the last fixture was installed.
Measurable results from the retrofit
The visual improvement is obvious, but the financial impact from the lighting retrofit is equally impressive.
Based on the energy analysis and projected operating hours, Acorn Recognition achieved
- Projected five year energy savings greater than sixty thousand United States dollars
- Return on investment of about seven point three months
In practical terms the LIBULBS LED lighting system paid for itself in well under one year. After that, the ongoing reduction in electric use continues to deliver savings.
These results come from
- Lower wattage per fixture compared with the previous lighting technology
- Consistent high output light that allows efficient use of the space
- Significantly reduced need for lamp and ballast replacements due to long LED life
How better lighting changed the production floor
Numbers tell one part of the story. The daily experience of people on the floor tells the rest.
With the new LIBULBS LED lighting system employees benefit from
- Clearer visibility for engraving and finishing small text and intricate logos
- Reduced eye strain over long shifts thanks to brighter, more uniform illumination
- Safer movement around racks, carts and machinery with dark corners eliminated
- A more modern, professional looking facility that reflects the quality of their products
Visitors and customers also notice the change. A bright organized production area strengthens confidence in the workmanship behind every plaque and award that leaves the building.
Project snapshot
- Customer Acorn Recognition
- Location 15 James CT Wilmington DE 19801
- Facility type Custom plaques and awards manufacturing
- Scope Production floor lighting retrofit with LIBULBS LED fixtures
- Projected five year savings More than sixty thousand United States dollars
- Return on investment Approximately seven point three months
What other small manufacturers can learn
The Acorn Recognition lighting retrofit offers clear lessons for other small manufacturers.
- Lighting is more than an overhead expense, it is a tool that affects quality, safety and morale
- Modern LIBULBS LED lighting can provide better performance and substantial energy savings
- A well planned retrofit in an older facility can achieve a very fast payback
If your plant or warehouse has flickering fixtures, yellow looking light, visible dark areas or constant lamp changes, it may be time to evaluate an LED lighting upgrade.
Considering a lighting retrofit for your own facility
Acorn Recognition shows that you do not need to run a massive factory to get powerful results from a lighting upgrade. With LIBULBS LED lighting they improved visibility, boosted comfort and secured more than sixty thousand United States dollars in projected five year savings with a payback measured in months.
If you manage a manufacturing, warehouse or production space and your lighting is holding you back, start with a simple review.
- Walk your facility and note areas that feel dim, uneven or uncomfortable to work in
- Gather recent electricity bills to understand your baseline consumption
- Connect with a trusted lighting partner who can model savings and recommend appropriate fixtures
Better light can be one of the most straightforward improvements you make to your operation. As Acorn Recognition discovered, a thoughtful LED lighting retrofit with LIBULBS can enhance both the workspace and the bottom line.