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Prepared by Outsourced Innovation, LLC
6/1/2011

The business information related to the findings in this report is confidential to Rose Acre Farms.
Results from this evaluation are specific to this location and at one point in time. More field
experience is required to make predictions on long-term technology reliability or validate other
product claims.
Table of Contents



1. Executive Summary
2. Background and Research Objectives
3. Recommendations
4. Methodology
       a. Dimming Schedule
       b. Baseline CFL Light and Power Quality Measurements
       c. CFL compared to LED Light Measurements and Power Quality
       d. Radiometric Measurements
5. Energy Savings
6. Lifecycle Analysis
7. Final Thoughts and Conclusions

     Appendix




                                       2
Rose Acre Farms – Cort Acres Complex

   1. Executive Summary

Recent advancements in solid-state lighting (SSL) provide new opportunities for achieving
energy efficiency, lowered maintenance costs and higher quality illumination for agricultural-
based applications.

The efficient use of energy has been an important goal for many initiatives at Hoosier Energy.
Customers look to their utility for ways to improve energy efficiency and implement new
technology that creates real value and contributes to a better environment.

Rose Acre Farms must be technically sound on new lighting technology selected because they
have to live with the results. If lights do not perform as claimed it can entail a detrimental
financial loss to operations and the utility that supports delivering reliable electric service.

A collaborative light emitting diode (LED) research project has been established between Rose
Acre Farms, Hoosier Energy and their distribution cooperative Jackson County REMC and the
LED lighting manufacturer Once Innovations. The project goal is to help understand and
communicate the benefits and performance of a new LED lighting system called AgriShift EL®
designed for egg-laying poultry facilities.

The LED research house selected (House #8) is home to about 80,000 hens within the Cort
Acres complex at Rose Acre Farms. That house was selected to compare against operations
within the remaining 34 houses lit with CFLs that will serve as the control group.

Initial results from the installation of 360, 3-watt poultry cage LED lights replacing 192, 9-watt
CFLs show the following results:



      100-hour LED light output measurements show AgriShift EL met performance claims on
       their datasheet at 100% light intensity delivering matched or better light output
       compared to CFLs.



      A forecasted 6,285 annual k/Wh savings from the modular LED lamps in House #8. If the
       entire Cort Acres complex was converted to AgriShift LEDs, it is projected that Rose
       Acres Farms could realize an annual dollar savings of about $17,430 primarily achieved

                                                 3
from the reduced wattage from LEDs and an estimated $100,000 savings from reduced
       maintenance costs over the projected 8-year service life of the LED lighting system,
       assuming that long service life holds true.

      Compared to the option of keeping the existing CFL lighting system in place, payback of
       4 years implies the technology is more expensive upfront for full-scale lamp
       conversions. The availability of utility incentives or energy efficiency grants can help to
       reduce payback calculations.

      The installation of the AgriShift LED lighting system shows a projected 20 year net
       present value (NPV) positive cost savings of $19.53 compared to CFLs and an Internal
       Rate of Return (IRR) of 20% indicating LEDs might be a good investment compared to
       other capital projects and especially if a positive behavioral response can be
       documented.

      Because measured differences in LED light intensities were detected from the high-tier
       cages versus the low-tier cages, behavioral changes in House #8 may be difficult to trace
       back to LED lighting. That may require further evaluation to assess differences in bird
       production of high-tier versus low tier cages and comparing results of the LED house to
       other CFL houses.



Industry methods to predict long-term LED fixture reliability are unclear implying that strong
product warranties are critical for an agricultural application. More time and experience is
required to predict if the AgriShift EL fixtures will continue to deliver to proposed EnergyStar
and Illuminating Society of North America (IESNA) standards of delivering 70% light output after
50,000 hours in this harsh environment.

Also, findings in this report are projections as an LM-79-08 Electrical and Photometric Report of
Solid State Products was not provided for the LED fixtures at this demonstration site. The
AgriShift EL products have not been safety tested by a nationally recognized testing lab
(Underwriters Laboratory, Intertek).




   2. Background and Objectives

Rose Acre Farms is home to over 3 million, cage-layer production hens at any given time and
prides itself on safe-cage farming. This includes protection from natural predators, hens having
constant access to fresh food, water and natural grains, automatic manure removal and other
farming operations that maximizes energy efficiency and reduces its carbon footprint. The
promise of LED lighting is a natural extension to its operations as they keep a close watch on
light intensity to create a calm atmosphere.

                                                4
The 2 year life span of CFLs compared to LEDs (10,000-15,000 versus 50,000) creates an added
maintenance cost for Rose Acre Farms as frequent replacement of CFL bulbs are needed
because of pre-mature failure or breakage. Further, LEDs are RoHS compliant meaning they
contain no heavy metals and unlike CFLs can be disposed or recycled without environmental
concerns.

The installed solid state lighting system is manufactured by Once Innovations, a Plymouth,
Minnesota based company. The new LED product is designed specifically for poultry
applications and is a 3-watt, AC based LED Poultry Cage Lighting system (refer to Appendix A for
spec sheet on AgriShift EL). The project was not a retrofit as it required the installation of new
conduit and a dimming system. The AC-based product was designed with the advantage of
easy integration to the complex’s existing electrical system and is suitable for very small-size
lamps. AgriShiftEL also has an Ingress Protection (IP) rating of IP66 indicating it suitable for dirt
and dust environments and wet or hose spray cleaning.

The legacy lighting in the Cort Acres complex is 17 years old and utilizes a bi-pin CFL lighting
system at more than 9 watts each and inefficient by today’s standards but needed for an
energy-saving lighting system required for a productive poultry application. New conduit was
installed to accommodate the modular LED lighting system that replaced existing CFL, GU23
pin-based sockets.

The LED lighting system is expected to demonstrate a more robust product that is conducive to
harsh environments, eliminates the risk of bulb breakage or mercury contamination, will show a
substantial energy savings and deliver a longer service life that could reduce facility
maintenance and disposal costs.

Beyond cost savings, the expectation is the LED system will demonstrate new value from LED-
based illumination. The LED product is built with selective dimming capabilities not seen with
CFLs and claims to provide a spectral light distribution that closely mimics the color sensitivities
of poultry. The hypothesis is that the unique wavelength of LEDs can be tailored to elicit
behavior changes that might stimulate increased weight gain, egg size or egg production.

Hoosier Energy and Jackson County REMC will be monitoring pre and post LED light levels,
lumen depreciation and power quality following the conversion to LEDs. Rose Acre Farms will
track and report fixture outages and reported behavior changes resulting from the conversion
to LED lighting, within the 80,000 hen facility and compare to results from the other 34 non-LED
houses. Project completion will occur after 1 year of power quality analysis.

Specific research objectives of the project include the following:

   1. Can a replacement of 9-watt CFLs with 3-watt LEDs produce an energy savings with an
      LED lighting system manufactured by Once Innovations?



                                                  5
2. Will photometry following the lighting conversion meet design guidelines of matched or
   surpassed light levels compared to CFLs, achieving .5 footcandles at the bottom-tier
   cage?

3. What is the actual energy savings following the conversion to AgriShift EL, especially
   resulting from new dimming capabilities of LEDs?

4. How will the conversion to an LED lighting system impact the electric load at Rose Acre
   Farm?

5. Will light levels hold up as well or better and long-term compared to CFLs within a harsh
   and dirty environment?

6. Does the different spectral intensity of LED lighting drive behavior and/or feeding
   changes for the new breed of birds that include the following:

       a.   Will LEDs maintain the same level of egg production?
       b.   Will the size or weight of eggs change as a result of LED lighting?
       c.   Will hens maintain body weight with the new flock of birds?
       d.   What is the impact of feed consumption in House 8, if any, resulting from the
            LED conversion?

3. Recommendations

   A one-time measurement after LED lights have been seasoned does not adequately
    predict long-term lamp reliability. To ensure steady state performance and mitigate
    risk, continue to monitor lumen maintenance at 1,000 hours, 6,000 and 10,000 hours,
    especially since proof of high temperature tests were not provided on the fixtures (LM-
    80 report).
   Consider evaluating the production and behavior performance of LEDs and CFLs in both
    high-tier cage hens versus low-tiered cage birds as light intensities were measured as
    being dramatically different.
   Monitor LED power and power quality in both the on and off state.
   Request a binning policy from the vendor and/or protection from droop (drop in
    efficiency that might occur when LEDs operate at high power).
   Make certain that LED lamps are UL rated before expansion of equipment into other
    houses within the complex to ensure the risk of electric shock or fire is properly
    addressed.
   Continue to monitor power quality at the LED test facility for at least one year. Full-
    scale adoption of LEDs could have the potential to reduce lighting load from 444,000
    k/Wh to 219,000 k/Wh if LED lights are deployed throughout all 35 houses within the
    Cort Acre complex.



                                            6
4. Research Methodology


House #8 was identified by Rose Acre Farms as an ideal house for evaluation of LED. The
current flock was mature and ready for transportation out so a direct behavior comparison
from a new flock would be in place. It is anticipated that the flock will stay in the LED test
facility through 2 regular productions and during short molting cycles with changes in feed and
light for the duration of the evaluation.

House #8 measures 500 feet long by 50 feet wide, having 6 rows of cages stacked 8 feet in
height, with 2 foot walkways between each row of cages. The facility occupied six rows of 9
watt, bi-pin CFL lights (model # F9BX/841- GE;CFL GU23), at 15.4 foot spacing and a ceiling
height of 9.5’.


 Lamp Type                     CFLs            LEDs – AgriShift EL
 # of Lamps                    192             360
 Spacing (feet)                15.4’           8.0’
 Input wattage (validated) 10.657 watts 2.923 watts (April); 2.700 watts (April – July 2011)




The old lighting system was removed and replaced with new conduit to accommodate the
AgriShift EL modular lighting system and Phason Controller to allow for dimming features.

The electrical configuration within House #8 consists of a 3-phase, 120 volts with 6 rows
monitored with each row on separate circuits. PMI (Power Monitors, Inc) Eagle 440 meters
were setup with alligator clips using 3-channels with each channel on its own single-phase
circuit to isolate lighting load. After the LEDs were installed, all six rows of lights were put on 1
single-phase breaker so 1 channel on the PMI recorder is used to monitor load in 15-second
intervals.

Illumination measurements were taken using a NIST traceable, research-grade Solar Light
Meter PMA 2100 with remote sensors for photopic and scotopic data recording. Radiometric
readings (light color and intensity) were also captured using Minolta Konica’s SpectraRad
Irradiance Meter as LED light intensity was a value added feature compared to CFLs.

Dimming Schedule

An important aspect to the research was to evaluate the impact of dimming on energy savings
and flock performance. Unlike the existing CFL system, LEDs can be dimmed. A dimming

                                                  7
schedule was established to mimic sunrise and sunset and leverage the added value of solid
state lighting by manipulating light levels to achieve a desired behavioral response.

The schedule in Table 1 below reflects how LED light levels were established during initial
growth weeks and in preparation for birds reaching 3 lbs, where the flock is considered
“production ready.” The long-term light cycle will entail 17.5 hours to create a gradual longer
daylight photoperiod with 1 hour for an additional late evening feed.
Table 1 – Cort Acres Complex LED Dimming Schedule

Initial Schedule (weeks 1 – 9)              Light Intensity          On-Time (14
                                                                     hrs)
6:00 a.m. – 6:30 a.m.                     0% to gradual 100%         ½ hour
6:30 a.m. – 6:30 p.m.                            100%                12 hrs
6:30 p.m. – 7:00 p.m.                     100% to gradual 0%         ½ hour
      7:00 p.m.                                Lights off
11:00 p.m. – 11:10 p.m.                   0% to gradual 100%         10 minutes
11:10 p.m. – 11:50 p.m.                          100%                40 minutes
11:50 p.m. – Midnight                     100% to gradual 0%         10 minutes
      Midnight                                 Lights off

Long-term Schedule (week 10                 Light Intensity          On-Time
and beyond)                                                          (17.5 hrs)
4:00 a.m. – 4:30 a.m.                      0 to gradual 100%         ½ hour
4:30 a.m. – 8:00 p.m.                             100%               15.5 hrs
8:00 p.m. – 8:30 p.m.                     100% to gradual 0%         ½ hour
     8:30 p.m.                                  Lights off
11:00 p.m. – 11:10 p.m.                   0% to gradual 100%         10 minutes
11:10 p.m. – 11:50 p.m.                           100%               40 minutes
11:50 – Midnight                          100% to gradual 0%         10 minutes
             Midnight                           Lights off




Baseline CFL Measurements

On December 6, 2010, baseline CFL light and power quality measurements were taken with
birds in place to compare against the LED conversion (Table 2) showing .9 – 1.2 average
footcandles from 80 light measurements taken at 6” above horizontal grade just prior to the
LED conversion. Power quality measurements were validated using a PMI Eagle meter for 7
days, in 15-second intervals validating power usage of CFLs and ballast at 10.657 watts each.


Table 2 – Baseline CFL Light Output and Power Quality Readings, House #8


                                                            8
Cort Acres
Baseline Readings Barn 8, Row 5
Performance Evaluation


DATE:                    12/6/2010                      Enclosed barn
TIME:              4:32 PM - 5:15 PM
TEMPERATURE:       52.7 deg F
HUMIDITY:                 91%
Lamp               9 Watt CFLs          GU23            Hours of Operation:       12 -16 hours   Power Quality Data Meters: PMI Eagle 440
                                                                                                 15-second intervals, 7 days of readings
Installed
FIXTURES           AVG.              MAX.      MIN.     MAX.        COEFFICIENT                  POWER                      INPUT
                   ILLUM.            ILLUM.    ILLUM.   TO          OF            UNIFORMITY FACTOR           THD           POWER
                   (FC)                                 MIN.        VARIATION          X:1                                  (WATTS/FIXTURE)
All Fixtures                                                                                          0.537          6.49        10.657
PHOTOPIC                  0.9            1.1      0.8        1.4         0.11          1.2
SCOTOPIC                  1.2            1.5      1.0        1.5         0.12          1.2




In preparation for LED conversion the facility was cleaned and disinfected before a new flock
was delivered. The flock will remain in place for 2 years which will allow for accurate house-to-
house comparison on behavior or egg production changes against the other CFL facilities.

New circuits, conduit and LED lamps were installed the week of April 11th with 100 hours of
burn time to season LEDs prior to a new flock entering the facility and taking initial 100-hour
LED measurements.



LED Light Output and Power Quality Measurements

Horizontal illumination measurements following the LED conversion shown in Table 3
demonstrates light levels that exceed CFLs at ground level. These readings were taken with the
AgriShift EL at 100% light intensity.

No photometric measurements were taken at 80% or 50% light intensity.




                                                                     9
Table 3 – 100 Hour LED Light and Power Measurements at Cort Acres, House #8

Cort Acres Farms
Baseline & 4-month Readings Barn 8, Row 5
Performance Evaluation - LED 100 hr test


DATE:                 4/22/2011                      Enclosed barn
TIME:              9:06 AM - 9:57 AM
TEMPERATURE:       64.9 deg F
HUMIDITY:               54%                                                                         Power Quality Data Meter PMI Eagle 440
Lamp                  Agrishift                      Hours of Operation:         13 hrs             15-second intervals
                                                     Week of LED Installation:            4/11/2011 4/18-29/2011; 4/18 - 7/24, 2011
Installed
FIXTURES           AVG.           MAX.      MIN.     MAX.        COEFFICIENT                        POWER                             INPUT
                   ILLUM.         ILLUM.    ILLUM.   TO          OF              UNIFORMITY         FACTOR           THD              POWER
                   (FC)                              MIN.        VARIATION                X:1                                         (WATTS/FIXTURE)
All Fixtures                                                                                         1 month 0.976          17.081            2.923
PHOTOPIC                  1.0         1.1      0.9        1.2         0.02                1.1       4 months 0 960         15.9322            2.701
SCOTOPIC                  1.3         1.4      1.2        1.2         0.04                1.1




Power quality validation also shows initial power draw for AgriShift EL at 2.923 watts (April,
2011), then dropping to 2.7006 (April – July, 2011) with initial power factor (PF) at .976 (April,
2011) and dropping to .9606 (April – July, 2011) and initial total harmonic distortion (THD)
17.081% (April, 2011) dropping to 15.932 (April – July, 2011). Initial reported power quality is
based on 11 days of 24/7 monitoring in 15-second intervals and included the average of 31,338
data points. Four-month reported power quality is based on 460,210 data points and 24/7
monitoring in 15-second intervals.



The side-by-side comparison of light output at both floor and mid-cage level measurements
from baseline CFLs versus LEDs are indicated in Table 4 below. The red circle indicates that LED
measurements easily met and surpassed the hurdle of .5 footcandles at floor level at 100% light
intensity.




                                                                      10
Table 4: CFL and LED Illumination Comparisons at Mid-Cage and Floor Level




LED Radiometric Readings

Radiometric readings show the spectral light distribution of the AgriShift EL product with the
dominant wavelength indicated at 570 nanometers and a Kelvin temperature of 4749. The
predominate findings from Figure 1 and Figure 2 was that light intensity at high cage was
different than low cage measurements but inconclusive if lower relative intensities for bottom
cage birds would impact hen performance, and not unlike what might occur with CFLs.

No radiometric readings were taken on CFLs for this evaluation.
Figure 1 – Cort Acres, High-Cage Light Intensity Readings (18” below light source)




Figure 2 – Cort                                                                      Acres, Low- Cage
Light Intensity (42’’                                                                directly below
light source)




                                                              11
It will be important to monitor if both LED and CFL light output is maintained and color is stable
to ensure these chromaticity measurements don’t shift over time or from excessive heat or
humidity from a harsh operational environment.



                                                12
5. Energy Savings

Based on measurement and validation work supporting this project it is estimated that this LED
research project will deliver a 50% energy savings in House #8. More LEDs and shorter spacing
was used to achieve the same or better targeted light levels than were delivered with CFLs.

The annual energy use for CFL versus LED is shown in Table 4.


Table 4 – Cort Acres Annual Energy Savings (validated w/power meters)

 Lamp Source              Number of            Input wattage*
                           Fixtures                                     Annual hrs k/Wh
CFLs                         192               10.65 watts              6,205      12,687
AgriShift LEDs               360               2.9 watts                6,132       6,401
Net Energy                                                                          50%
Savings


Further, even though more LED fixtures were utilized, the lighting power density in House # 8
went from 0.08 w/ft² to 0.04 w/ft² to demonstrate the directionality and optical efficiency of
the AgriShift LED lighting system.



    6. Lifecycle Cost Analysis

While technical performance of LEDs in House #8 is critical to technology adoption at Rose Acre
Farms, purchasers likely will look at financial performance first.

In LED conversion new application installations, product lifetime and reliability are critical
contributors to a financial analysis. This is especially true when payback is measured in years,
where long warranties are a business necessity and where reduced maintenance costs creates a
significant portion of the return on investment. Also, since in theory, the LEDs are expected to
last 3-5 times longer than conventional CFLs, lighting maintenance costs could be potentially
lower.

The key financial metrics of payback period are discussed below to help understand if LED
technology today makes financial sense for Rose Acre Farms. An economic analysis will help
Rose Acre Farms make a decision to invest in an LED lighting system throughout all 35 houses
within the Cort Acres complex or keep the existing CFL lights in place.



The lifecycle analysis takes into account the following assumptions as indicated in Table 5.

                                                          13
Table 5 – Financial Assumptions

                                                                 CFL                                               AgriShift EL
     Validated Input wattage                                 10.65 watts                                            2.9 watts
     Base Rate (k/Wh)                                           0.566                                                0.0566
     Demand charge per kW                                      $ 11.89                                               $11.89
     Rated Useful Life (hrs.)                             10,000                                                  50,000
     Labor Rate                                            $65                                                      $65
     Labor hours to replace                                 .16                                                     .20
     Inflation rate for electricity                         3%                                                      3%
     Cost of capital                                       10%                                                     10%
     Lamp cost                                   $2 (new bulb replacement                                      $28 (includes
                                                   and disposal of CFLs)                                     conduit/dimmer)


The applicable general base rate from Jackson County REMC for Rose Acre Farms is 0.566 k/Wh
and demand charge of $11.89 kW.


                            9 watt CFL                                       3 watt Agrishift
                     Year           EnergyLabor & material   Present value            Energy Labor & material       Present value
                     2010           $0.00            $8.50          $7.73            $0.00               $41.00           $37.27
                     2011           $5.18            $0.00          $4.28            $1.37                $0.00            $1.13
                     2012           $5.34            $8.50         $10.39            $1.41                $0.00            $1.06
                     2013           $5.50            $0.00          $3.75            $1.45                $0.00            $0.99
                     2014           $5.66            $8.50          $8.79            $1.49                $0.00            $0.93
                     2015           $5.83            $0.00          $3.29            $1.54                $0.00            $0.87
                     2016           $6.01            $8.50          $7.44            $1.58                $0.00            $0.81
                     2017           $6.19            $0.00          $2.89            $1.63                $0.00            $0.76
                     2018           $6.37            $8.50          $6.31            $1.68               $28.00           $12.59
                     2019           $6.56            $0.00          $2.53            $1.73                $0.00            $0.67
                     2020           $6.76            $8.50          $5.35            $1.78                $0.00            $0.62
                     2021           $6.96            $0.00          $2.22            $1.84                $0.00            $0.59
                     2022           $7.17            $8.50          $4.54            $1.89                $0.00            $0.55
                     2023           $7.39            $0.00          $1.94            $1.95                $0.00            $0.51
                     2024           $7.61            $8.50          $3.86            $2.01                $0.00            $0.48
                     2025           $7.84            $0.00          $1.71            $2.07                $0.00            $0.45
                     2026           $8.07            $8.50          $3.28            $2.13               $23.00            $4.97
                     2027           $8.31            $0.00          $1.50            $2.19                $0.00            $0.39
                     2028           $8.56            $8.50          $2.79            $2.26                $0.00            $0.37
                     2029           $8.82            $0.00          $1.31            $2.33                $0.00            $0.35
                                NPV of costs over 20 years         $85.89        NPV of costs over 20 years               $66.36
                                                                                        Internal rate of return^          19.7%
                                                                         Simple payback/years to breakeven                     4
                                                                                  2 yr return on investment^^            -88.3%
                                                                                  5 yr return on investment^^              1.4%
                                                                                10 yr return on investment^^              37.7%
                                                                                20 yr return on investment^^             273.2%




                                                                      14
The entire 360 LED lighting system is projected to save 6,285 kWh each year for an annual
energy savings in House #8 of $498 ($356 k/Wh savings and $142 in kW savings) . If LEDs were
deployed throughout the entire Cort Acres complex, Rose Acre Farms could realize a cost
savings of $17,395 from using less wattage, because compared to the current CFL lighting in
place, a new LED system is expected to use 50% less energy.

The maintenance cost savings are expected to be the most important component of the value
of LED lighting. With a 50,000 hour rated lifetime, the AgriShift LEDs are expected to last 3-5
times longer than CFLs. Rose Acre Farms could realize a potential $100K in maintenance cost
savings over the 8-year service life of LEDs if they were deployed through the entire Cort Acres
complex assuming lumen output is maintained and product reliability is achieved as claimed by
the manufacturer.

The LED conversion projects a 4 year payback and illustrates the importance of utility rebates to
incentivize deployment of agricultural-based solid state lighting. The project estimates a 20-
Year Net Present Value (NPV) positive cost savings of $19.53 for LED and an Internal Rate of
Return (IRR) of almost 20% suggesting a favorable return on this capital project compared to
investing in a bank certificate of deposit.

For full-scale technology deployment, some poultry farming operations will require LEDs to
come down in price unless utility incentives, grants, or outside financing can be applied.
Further, the total projected savings are based on the assumption that the LED system is reliable
in the field and more time and experience is needed to verify this.

LED technology is reported as following Haitz Law which suggests that light output increases by
a factor of 20 and costs decrease by a factor of 10 every 10 years (DOE SSL Projections). This
has financial implications for projected future capital investments and perhaps will help to
make solid-state lighting technology a more realistic business decision with higher cost being
less of a market barrier to full-scale adoption within the coming years.



   7. Final Thoughts and Conclusions

The primary conclusion from this research project is LED lighting systems, although more
expensive upfront will deliver a 50% energy savings to Rose Acre Farm while achieving higher
light levels and better illumination and could deliver added value through reduced maintenance
and disposal costs.

The AgriShift EL product being AC based does not require a driver. That could provide an
advantage of delivering a longer service life compared to other more typical DC based LED
products that do.

The value of dimming at this test site is inconclusive at this time as light levels of less than 100%
intensity may not be acceptable to Rose Acre Farms operations. However, there may be some
detectable advantages on bird welfare and productivity from leveraging LED dimming
capabilities at sunrise and sunset.

                                                 15
The LED chip manufacturer (Epistar) reports dramatic improvement in lumens per watt from
the LED chip utilized in the current AgriShift EL product. This raises a potential question of how
to address lamp upgrades in House #8 as technology improves.

Anecdotally, impressions of the LED lighting have been favorable suggesting that continued
deployment of LED lighting could be acceptable to not only hens but also employees of Rose
Acre Farm.

Emerging technology demonstrations such as the one in the Cort Acres complex provides
valuable insights regarding the performance of emerging solid-state lighting technology. A
simple misstep in design of immature technology can cause LEDs life to end prematurely.
Lessons learned from this and other LED research projects include the following:

      Laboratory testing suggests that useful life of LED fixtures should, in theory, reach a
       minimum of 50,000 hours. There is insufficient experience at this test location to
       substantiate those claims as more time and real-world demonstrations are required to
       back reliability claims. The DOE is comfortable with useful life claims of 35,000 hours
       and not beyond that. Also, there were no LM-79 reports submitted for AgriShift EL.
       Strong product warranties are essential to mitigate the risk of early system failure, with
       other LED manufacturers providing warranties that are longer than 3 years.



      Weather extremes and frequent lightning can be common to Seymour, Indiana and
       within the Cort Acres complex. It will be important to understand and monitor if
       adequately rated ceramic capacitors are designed within the AgriShift lighting system
       and how SSL can be exposed to extreme surge conditions such as power-line lightning
       strikes so an LED lighting system doesn’t fail prematurely.



      The Department of Energy continues to report a wide variability in product performance
       and performance claims that are untrue to specs (DOE Caliper Report #11). That may
       not hold true to this project as early light output and power measurements are accurate
       but necessitates the importance of good measurement and validation procedures over
       time and evaluating multiple products before making a scalable purchase of emerging
       lighting technologies.




                                                16
Schematic of House #8




                  Total power:           3W
                  Equivalence:           20W incandescent
                  Harmonic Distortion:   < 20%
                  Power Factor:          > 0.97
                  Dimming:               100 to 1%, smooth transition
                                         Semi linear behavior




                                                                17

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Outsourced Innovation Case Study-Rose Acre Farm

  • 1. Prepared by Outsourced Innovation, LLC 6/1/2011 The business information related to the findings in this report is confidential to Rose Acre Farms. Results from this evaluation are specific to this location and at one point in time. More field experience is required to make predictions on long-term technology reliability or validate other product claims.
  • 2. Table of Contents 1. Executive Summary 2. Background and Research Objectives 3. Recommendations 4. Methodology a. Dimming Schedule b. Baseline CFL Light and Power Quality Measurements c. CFL compared to LED Light Measurements and Power Quality d. Radiometric Measurements 5. Energy Savings 6. Lifecycle Analysis 7. Final Thoughts and Conclusions Appendix 2
  • 3. Rose Acre Farms – Cort Acres Complex 1. Executive Summary Recent advancements in solid-state lighting (SSL) provide new opportunities for achieving energy efficiency, lowered maintenance costs and higher quality illumination for agricultural- based applications. The efficient use of energy has been an important goal for many initiatives at Hoosier Energy. Customers look to their utility for ways to improve energy efficiency and implement new technology that creates real value and contributes to a better environment. Rose Acre Farms must be technically sound on new lighting technology selected because they have to live with the results. If lights do not perform as claimed it can entail a detrimental financial loss to operations and the utility that supports delivering reliable electric service. A collaborative light emitting diode (LED) research project has been established between Rose Acre Farms, Hoosier Energy and their distribution cooperative Jackson County REMC and the LED lighting manufacturer Once Innovations. The project goal is to help understand and communicate the benefits and performance of a new LED lighting system called AgriShift EL® designed for egg-laying poultry facilities. The LED research house selected (House #8) is home to about 80,000 hens within the Cort Acres complex at Rose Acre Farms. That house was selected to compare against operations within the remaining 34 houses lit with CFLs that will serve as the control group. Initial results from the installation of 360, 3-watt poultry cage LED lights replacing 192, 9-watt CFLs show the following results:  100-hour LED light output measurements show AgriShift EL met performance claims on their datasheet at 100% light intensity delivering matched or better light output compared to CFLs.  A forecasted 6,285 annual k/Wh savings from the modular LED lamps in House #8. If the entire Cort Acres complex was converted to AgriShift LEDs, it is projected that Rose Acres Farms could realize an annual dollar savings of about $17,430 primarily achieved 3
  • 4. from the reduced wattage from LEDs and an estimated $100,000 savings from reduced maintenance costs over the projected 8-year service life of the LED lighting system, assuming that long service life holds true.  Compared to the option of keeping the existing CFL lighting system in place, payback of 4 years implies the technology is more expensive upfront for full-scale lamp conversions. The availability of utility incentives or energy efficiency grants can help to reduce payback calculations.  The installation of the AgriShift LED lighting system shows a projected 20 year net present value (NPV) positive cost savings of $19.53 compared to CFLs and an Internal Rate of Return (IRR) of 20% indicating LEDs might be a good investment compared to other capital projects and especially if a positive behavioral response can be documented.  Because measured differences in LED light intensities were detected from the high-tier cages versus the low-tier cages, behavioral changes in House #8 may be difficult to trace back to LED lighting. That may require further evaluation to assess differences in bird production of high-tier versus low tier cages and comparing results of the LED house to other CFL houses. Industry methods to predict long-term LED fixture reliability are unclear implying that strong product warranties are critical for an agricultural application. More time and experience is required to predict if the AgriShift EL fixtures will continue to deliver to proposed EnergyStar and Illuminating Society of North America (IESNA) standards of delivering 70% light output after 50,000 hours in this harsh environment. Also, findings in this report are projections as an LM-79-08 Electrical and Photometric Report of Solid State Products was not provided for the LED fixtures at this demonstration site. The AgriShift EL products have not been safety tested by a nationally recognized testing lab (Underwriters Laboratory, Intertek). 2. Background and Objectives Rose Acre Farms is home to over 3 million, cage-layer production hens at any given time and prides itself on safe-cage farming. This includes protection from natural predators, hens having constant access to fresh food, water and natural grains, automatic manure removal and other farming operations that maximizes energy efficiency and reduces its carbon footprint. The promise of LED lighting is a natural extension to its operations as they keep a close watch on light intensity to create a calm atmosphere. 4
  • 5. The 2 year life span of CFLs compared to LEDs (10,000-15,000 versus 50,000) creates an added maintenance cost for Rose Acre Farms as frequent replacement of CFL bulbs are needed because of pre-mature failure or breakage. Further, LEDs are RoHS compliant meaning they contain no heavy metals and unlike CFLs can be disposed or recycled without environmental concerns. The installed solid state lighting system is manufactured by Once Innovations, a Plymouth, Minnesota based company. The new LED product is designed specifically for poultry applications and is a 3-watt, AC based LED Poultry Cage Lighting system (refer to Appendix A for spec sheet on AgriShift EL). The project was not a retrofit as it required the installation of new conduit and a dimming system. The AC-based product was designed with the advantage of easy integration to the complex’s existing electrical system and is suitable for very small-size lamps. AgriShiftEL also has an Ingress Protection (IP) rating of IP66 indicating it suitable for dirt and dust environments and wet or hose spray cleaning. The legacy lighting in the Cort Acres complex is 17 years old and utilizes a bi-pin CFL lighting system at more than 9 watts each and inefficient by today’s standards but needed for an energy-saving lighting system required for a productive poultry application. New conduit was installed to accommodate the modular LED lighting system that replaced existing CFL, GU23 pin-based sockets. The LED lighting system is expected to demonstrate a more robust product that is conducive to harsh environments, eliminates the risk of bulb breakage or mercury contamination, will show a substantial energy savings and deliver a longer service life that could reduce facility maintenance and disposal costs. Beyond cost savings, the expectation is the LED system will demonstrate new value from LED- based illumination. The LED product is built with selective dimming capabilities not seen with CFLs and claims to provide a spectral light distribution that closely mimics the color sensitivities of poultry. The hypothesis is that the unique wavelength of LEDs can be tailored to elicit behavior changes that might stimulate increased weight gain, egg size or egg production. Hoosier Energy and Jackson County REMC will be monitoring pre and post LED light levels, lumen depreciation and power quality following the conversion to LEDs. Rose Acre Farms will track and report fixture outages and reported behavior changes resulting from the conversion to LED lighting, within the 80,000 hen facility and compare to results from the other 34 non-LED houses. Project completion will occur after 1 year of power quality analysis. Specific research objectives of the project include the following: 1. Can a replacement of 9-watt CFLs with 3-watt LEDs produce an energy savings with an LED lighting system manufactured by Once Innovations? 5
  • 6. 2. Will photometry following the lighting conversion meet design guidelines of matched or surpassed light levels compared to CFLs, achieving .5 footcandles at the bottom-tier cage? 3. What is the actual energy savings following the conversion to AgriShift EL, especially resulting from new dimming capabilities of LEDs? 4. How will the conversion to an LED lighting system impact the electric load at Rose Acre Farm? 5. Will light levels hold up as well or better and long-term compared to CFLs within a harsh and dirty environment? 6. Does the different spectral intensity of LED lighting drive behavior and/or feeding changes for the new breed of birds that include the following: a. Will LEDs maintain the same level of egg production? b. Will the size or weight of eggs change as a result of LED lighting? c. Will hens maintain body weight with the new flock of birds? d. What is the impact of feed consumption in House 8, if any, resulting from the LED conversion? 3. Recommendations  A one-time measurement after LED lights have been seasoned does not adequately predict long-term lamp reliability. To ensure steady state performance and mitigate risk, continue to monitor lumen maintenance at 1,000 hours, 6,000 and 10,000 hours, especially since proof of high temperature tests were not provided on the fixtures (LM- 80 report).  Consider evaluating the production and behavior performance of LEDs and CFLs in both high-tier cage hens versus low-tiered cage birds as light intensities were measured as being dramatically different.  Monitor LED power and power quality in both the on and off state.  Request a binning policy from the vendor and/or protection from droop (drop in efficiency that might occur when LEDs operate at high power).  Make certain that LED lamps are UL rated before expansion of equipment into other houses within the complex to ensure the risk of electric shock or fire is properly addressed.  Continue to monitor power quality at the LED test facility for at least one year. Full- scale adoption of LEDs could have the potential to reduce lighting load from 444,000 k/Wh to 219,000 k/Wh if LED lights are deployed throughout all 35 houses within the Cort Acre complex. 6
  • 7. 4. Research Methodology House #8 was identified by Rose Acre Farms as an ideal house for evaluation of LED. The current flock was mature and ready for transportation out so a direct behavior comparison from a new flock would be in place. It is anticipated that the flock will stay in the LED test facility through 2 regular productions and during short molting cycles with changes in feed and light for the duration of the evaluation. House #8 measures 500 feet long by 50 feet wide, having 6 rows of cages stacked 8 feet in height, with 2 foot walkways between each row of cages. The facility occupied six rows of 9 watt, bi-pin CFL lights (model # F9BX/841- GE;CFL GU23), at 15.4 foot spacing and a ceiling height of 9.5’. Lamp Type CFLs LEDs – AgriShift EL # of Lamps 192 360 Spacing (feet) 15.4’ 8.0’ Input wattage (validated) 10.657 watts 2.923 watts (April); 2.700 watts (April – July 2011) The old lighting system was removed and replaced with new conduit to accommodate the AgriShift EL modular lighting system and Phason Controller to allow for dimming features. The electrical configuration within House #8 consists of a 3-phase, 120 volts with 6 rows monitored with each row on separate circuits. PMI (Power Monitors, Inc) Eagle 440 meters were setup with alligator clips using 3-channels with each channel on its own single-phase circuit to isolate lighting load. After the LEDs were installed, all six rows of lights were put on 1 single-phase breaker so 1 channel on the PMI recorder is used to monitor load in 15-second intervals. Illumination measurements were taken using a NIST traceable, research-grade Solar Light Meter PMA 2100 with remote sensors for photopic and scotopic data recording. Radiometric readings (light color and intensity) were also captured using Minolta Konica’s SpectraRad Irradiance Meter as LED light intensity was a value added feature compared to CFLs. Dimming Schedule An important aspect to the research was to evaluate the impact of dimming on energy savings and flock performance. Unlike the existing CFL system, LEDs can be dimmed. A dimming 7
  • 8. schedule was established to mimic sunrise and sunset and leverage the added value of solid state lighting by manipulating light levels to achieve a desired behavioral response. The schedule in Table 1 below reflects how LED light levels were established during initial growth weeks and in preparation for birds reaching 3 lbs, where the flock is considered “production ready.” The long-term light cycle will entail 17.5 hours to create a gradual longer daylight photoperiod with 1 hour for an additional late evening feed. Table 1 – Cort Acres Complex LED Dimming Schedule Initial Schedule (weeks 1 – 9) Light Intensity On-Time (14 hrs) 6:00 a.m. – 6:30 a.m. 0% to gradual 100% ½ hour 6:30 a.m. – 6:30 p.m. 100% 12 hrs 6:30 p.m. – 7:00 p.m. 100% to gradual 0% ½ hour 7:00 p.m. Lights off 11:00 p.m. – 11:10 p.m. 0% to gradual 100% 10 minutes 11:10 p.m. – 11:50 p.m. 100% 40 minutes 11:50 p.m. – Midnight 100% to gradual 0% 10 minutes Midnight Lights off Long-term Schedule (week 10 Light Intensity On-Time and beyond) (17.5 hrs) 4:00 a.m. – 4:30 a.m. 0 to gradual 100% ½ hour 4:30 a.m. – 8:00 p.m. 100% 15.5 hrs 8:00 p.m. – 8:30 p.m. 100% to gradual 0% ½ hour 8:30 p.m. Lights off 11:00 p.m. – 11:10 p.m. 0% to gradual 100% 10 minutes 11:10 p.m. – 11:50 p.m. 100% 40 minutes 11:50 – Midnight 100% to gradual 0% 10 minutes Midnight Lights off Baseline CFL Measurements On December 6, 2010, baseline CFL light and power quality measurements were taken with birds in place to compare against the LED conversion (Table 2) showing .9 – 1.2 average footcandles from 80 light measurements taken at 6” above horizontal grade just prior to the LED conversion. Power quality measurements were validated using a PMI Eagle meter for 7 days, in 15-second intervals validating power usage of CFLs and ballast at 10.657 watts each. Table 2 – Baseline CFL Light Output and Power Quality Readings, House #8 8
  • 9. Cort Acres Baseline Readings Barn 8, Row 5 Performance Evaluation DATE: 12/6/2010 Enclosed barn TIME: 4:32 PM - 5:15 PM TEMPERATURE: 52.7 deg F HUMIDITY: 91% Lamp 9 Watt CFLs GU23 Hours of Operation: 12 -16 hours Power Quality Data Meters: PMI Eagle 440 15-second intervals, 7 days of readings Installed FIXTURES AVG. MAX. MIN. MAX. COEFFICIENT POWER INPUT ILLUM. ILLUM. ILLUM. TO OF UNIFORMITY FACTOR THD POWER (FC) MIN. VARIATION X:1 (WATTS/FIXTURE) All Fixtures 0.537 6.49 10.657 PHOTOPIC 0.9 1.1 0.8 1.4 0.11 1.2 SCOTOPIC 1.2 1.5 1.0 1.5 0.12 1.2 In preparation for LED conversion the facility was cleaned and disinfected before a new flock was delivered. The flock will remain in place for 2 years which will allow for accurate house-to- house comparison on behavior or egg production changes against the other CFL facilities. New circuits, conduit and LED lamps were installed the week of April 11th with 100 hours of burn time to season LEDs prior to a new flock entering the facility and taking initial 100-hour LED measurements. LED Light Output and Power Quality Measurements Horizontal illumination measurements following the LED conversion shown in Table 3 demonstrates light levels that exceed CFLs at ground level. These readings were taken with the AgriShift EL at 100% light intensity. No photometric measurements were taken at 80% or 50% light intensity. 9
  • 10. Table 3 – 100 Hour LED Light and Power Measurements at Cort Acres, House #8 Cort Acres Farms Baseline & 4-month Readings Barn 8, Row 5 Performance Evaluation - LED 100 hr test DATE: 4/22/2011 Enclosed barn TIME: 9:06 AM - 9:57 AM TEMPERATURE: 64.9 deg F HUMIDITY: 54% Power Quality Data Meter PMI Eagle 440 Lamp Agrishift Hours of Operation: 13 hrs 15-second intervals Week of LED Installation: 4/11/2011 4/18-29/2011; 4/18 - 7/24, 2011 Installed FIXTURES AVG. MAX. MIN. MAX. COEFFICIENT POWER INPUT ILLUM. ILLUM. ILLUM. TO OF UNIFORMITY FACTOR THD POWER (FC) MIN. VARIATION X:1 (WATTS/FIXTURE) All Fixtures 1 month 0.976 17.081 2.923 PHOTOPIC 1.0 1.1 0.9 1.2 0.02 1.1 4 months 0 960 15.9322 2.701 SCOTOPIC 1.3 1.4 1.2 1.2 0.04 1.1 Power quality validation also shows initial power draw for AgriShift EL at 2.923 watts (April, 2011), then dropping to 2.7006 (April – July, 2011) with initial power factor (PF) at .976 (April, 2011) and dropping to .9606 (April – July, 2011) and initial total harmonic distortion (THD) 17.081% (April, 2011) dropping to 15.932 (April – July, 2011). Initial reported power quality is based on 11 days of 24/7 monitoring in 15-second intervals and included the average of 31,338 data points. Four-month reported power quality is based on 460,210 data points and 24/7 monitoring in 15-second intervals. The side-by-side comparison of light output at both floor and mid-cage level measurements from baseline CFLs versus LEDs are indicated in Table 4 below. The red circle indicates that LED measurements easily met and surpassed the hurdle of .5 footcandles at floor level at 100% light intensity. 10
  • 11. Table 4: CFL and LED Illumination Comparisons at Mid-Cage and Floor Level LED Radiometric Readings Radiometric readings show the spectral light distribution of the AgriShift EL product with the dominant wavelength indicated at 570 nanometers and a Kelvin temperature of 4749. The predominate findings from Figure 1 and Figure 2 was that light intensity at high cage was different than low cage measurements but inconclusive if lower relative intensities for bottom cage birds would impact hen performance, and not unlike what might occur with CFLs. No radiometric readings were taken on CFLs for this evaluation. Figure 1 – Cort Acres, High-Cage Light Intensity Readings (18” below light source) Figure 2 – Cort Acres, Low- Cage Light Intensity (42’’ directly below light source) 11
  • 12. It will be important to monitor if both LED and CFL light output is maintained and color is stable to ensure these chromaticity measurements don’t shift over time or from excessive heat or humidity from a harsh operational environment. 12
  • 13. 5. Energy Savings Based on measurement and validation work supporting this project it is estimated that this LED research project will deliver a 50% energy savings in House #8. More LEDs and shorter spacing was used to achieve the same or better targeted light levels than were delivered with CFLs. The annual energy use for CFL versus LED is shown in Table 4. Table 4 – Cort Acres Annual Energy Savings (validated w/power meters) Lamp Source Number of Input wattage* Fixtures Annual hrs k/Wh CFLs 192 10.65 watts 6,205 12,687 AgriShift LEDs 360 2.9 watts 6,132 6,401 Net Energy 50% Savings Further, even though more LED fixtures were utilized, the lighting power density in House # 8 went from 0.08 w/ft² to 0.04 w/ft² to demonstrate the directionality and optical efficiency of the AgriShift LED lighting system. 6. Lifecycle Cost Analysis While technical performance of LEDs in House #8 is critical to technology adoption at Rose Acre Farms, purchasers likely will look at financial performance first. In LED conversion new application installations, product lifetime and reliability are critical contributors to a financial analysis. This is especially true when payback is measured in years, where long warranties are a business necessity and where reduced maintenance costs creates a significant portion of the return on investment. Also, since in theory, the LEDs are expected to last 3-5 times longer than conventional CFLs, lighting maintenance costs could be potentially lower. The key financial metrics of payback period are discussed below to help understand if LED technology today makes financial sense for Rose Acre Farms. An economic analysis will help Rose Acre Farms make a decision to invest in an LED lighting system throughout all 35 houses within the Cort Acres complex or keep the existing CFL lights in place. The lifecycle analysis takes into account the following assumptions as indicated in Table 5. 13
  • 14. Table 5 – Financial Assumptions CFL AgriShift EL Validated Input wattage 10.65 watts 2.9 watts Base Rate (k/Wh) 0.566 0.0566 Demand charge per kW $ 11.89 $11.89 Rated Useful Life (hrs.) 10,000 50,000 Labor Rate $65 $65 Labor hours to replace .16 .20 Inflation rate for electricity 3% 3% Cost of capital 10% 10% Lamp cost $2 (new bulb replacement $28 (includes and disposal of CFLs) conduit/dimmer) The applicable general base rate from Jackson County REMC for Rose Acre Farms is 0.566 k/Wh and demand charge of $11.89 kW. 9 watt CFL 3 watt Agrishift Year EnergyLabor & material Present value Energy Labor & material Present value 2010 $0.00 $8.50 $7.73 $0.00 $41.00 $37.27 2011 $5.18 $0.00 $4.28 $1.37 $0.00 $1.13 2012 $5.34 $8.50 $10.39 $1.41 $0.00 $1.06 2013 $5.50 $0.00 $3.75 $1.45 $0.00 $0.99 2014 $5.66 $8.50 $8.79 $1.49 $0.00 $0.93 2015 $5.83 $0.00 $3.29 $1.54 $0.00 $0.87 2016 $6.01 $8.50 $7.44 $1.58 $0.00 $0.81 2017 $6.19 $0.00 $2.89 $1.63 $0.00 $0.76 2018 $6.37 $8.50 $6.31 $1.68 $28.00 $12.59 2019 $6.56 $0.00 $2.53 $1.73 $0.00 $0.67 2020 $6.76 $8.50 $5.35 $1.78 $0.00 $0.62 2021 $6.96 $0.00 $2.22 $1.84 $0.00 $0.59 2022 $7.17 $8.50 $4.54 $1.89 $0.00 $0.55 2023 $7.39 $0.00 $1.94 $1.95 $0.00 $0.51 2024 $7.61 $8.50 $3.86 $2.01 $0.00 $0.48 2025 $7.84 $0.00 $1.71 $2.07 $0.00 $0.45 2026 $8.07 $8.50 $3.28 $2.13 $23.00 $4.97 2027 $8.31 $0.00 $1.50 $2.19 $0.00 $0.39 2028 $8.56 $8.50 $2.79 $2.26 $0.00 $0.37 2029 $8.82 $0.00 $1.31 $2.33 $0.00 $0.35 NPV of costs over 20 years $85.89 NPV of costs over 20 years $66.36 Internal rate of return^ 19.7% Simple payback/years to breakeven 4 2 yr return on investment^^ -88.3% 5 yr return on investment^^ 1.4% 10 yr return on investment^^ 37.7% 20 yr return on investment^^ 273.2% 14
  • 15. The entire 360 LED lighting system is projected to save 6,285 kWh each year for an annual energy savings in House #8 of $498 ($356 k/Wh savings and $142 in kW savings) . If LEDs were deployed throughout the entire Cort Acres complex, Rose Acre Farms could realize a cost savings of $17,395 from using less wattage, because compared to the current CFL lighting in place, a new LED system is expected to use 50% less energy. The maintenance cost savings are expected to be the most important component of the value of LED lighting. With a 50,000 hour rated lifetime, the AgriShift LEDs are expected to last 3-5 times longer than CFLs. Rose Acre Farms could realize a potential $100K in maintenance cost savings over the 8-year service life of LEDs if they were deployed through the entire Cort Acres complex assuming lumen output is maintained and product reliability is achieved as claimed by the manufacturer. The LED conversion projects a 4 year payback and illustrates the importance of utility rebates to incentivize deployment of agricultural-based solid state lighting. The project estimates a 20- Year Net Present Value (NPV) positive cost savings of $19.53 for LED and an Internal Rate of Return (IRR) of almost 20% suggesting a favorable return on this capital project compared to investing in a bank certificate of deposit. For full-scale technology deployment, some poultry farming operations will require LEDs to come down in price unless utility incentives, grants, or outside financing can be applied. Further, the total projected savings are based on the assumption that the LED system is reliable in the field and more time and experience is needed to verify this. LED technology is reported as following Haitz Law which suggests that light output increases by a factor of 20 and costs decrease by a factor of 10 every 10 years (DOE SSL Projections). This has financial implications for projected future capital investments and perhaps will help to make solid-state lighting technology a more realistic business decision with higher cost being less of a market barrier to full-scale adoption within the coming years. 7. Final Thoughts and Conclusions The primary conclusion from this research project is LED lighting systems, although more expensive upfront will deliver a 50% energy savings to Rose Acre Farm while achieving higher light levels and better illumination and could deliver added value through reduced maintenance and disposal costs. The AgriShift EL product being AC based does not require a driver. That could provide an advantage of delivering a longer service life compared to other more typical DC based LED products that do. The value of dimming at this test site is inconclusive at this time as light levels of less than 100% intensity may not be acceptable to Rose Acre Farms operations. However, there may be some detectable advantages on bird welfare and productivity from leveraging LED dimming capabilities at sunrise and sunset. 15
  • 16. The LED chip manufacturer (Epistar) reports dramatic improvement in lumens per watt from the LED chip utilized in the current AgriShift EL product. This raises a potential question of how to address lamp upgrades in House #8 as technology improves. Anecdotally, impressions of the LED lighting have been favorable suggesting that continued deployment of LED lighting could be acceptable to not only hens but also employees of Rose Acre Farm. Emerging technology demonstrations such as the one in the Cort Acres complex provides valuable insights regarding the performance of emerging solid-state lighting technology. A simple misstep in design of immature technology can cause LEDs life to end prematurely. Lessons learned from this and other LED research projects include the following:  Laboratory testing suggests that useful life of LED fixtures should, in theory, reach a minimum of 50,000 hours. There is insufficient experience at this test location to substantiate those claims as more time and real-world demonstrations are required to back reliability claims. The DOE is comfortable with useful life claims of 35,000 hours and not beyond that. Also, there were no LM-79 reports submitted for AgriShift EL. Strong product warranties are essential to mitigate the risk of early system failure, with other LED manufacturers providing warranties that are longer than 3 years.  Weather extremes and frequent lightning can be common to Seymour, Indiana and within the Cort Acres complex. It will be important to understand and monitor if adequately rated ceramic capacitors are designed within the AgriShift lighting system and how SSL can be exposed to extreme surge conditions such as power-line lightning strikes so an LED lighting system doesn’t fail prematurely.  The Department of Energy continues to report a wide variability in product performance and performance claims that are untrue to specs (DOE Caliper Report #11). That may not hold true to this project as early light output and power measurements are accurate but necessitates the importance of good measurement and validation procedures over time and evaluating multiple products before making a scalable purchase of emerging lighting technologies. 16
  • 17. Schematic of House #8 Total power: 3W Equivalence: 20W incandescent Harmonic Distortion: < 20% Power Factor: > 0.97 Dimming: 100 to 1%, smooth transition Semi linear behavior 17