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Production floor at Acorn Recognition with LIBULBS LED fixtures in operation 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. Installer gives thumbs up after new LIBULBS flat panel install in office 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. New LIBULBS round high bay fixture mounted overhead 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. Close view of LIBULBS round high bay lighting fixture 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. LIBULBS LED panel brightens corridor ceiling at Acorn Recognition 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. LIBULBS LED panel above office window at Acorn Recognition 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.