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HanesBrands Inc. Distribution Center




CSX2-LED-120C 1000-40K T3MVOLT HS

Part Night Dusk to Dawn Photo Sensor and Controller

SensorSwitch Motion Sensors

Fixture warranty

Five years

Annual energy savings


Five-year energy savings


Return on investment

1.2 years

HanesBrands (HBI) Corporate Engineering staff reached out to Shealy Electrical — now Border States — in Kernersville, North Carolina, with request for assistance in designing a lighting project for a 15-acre parking lot at their distribution center in Rural Hall, North Carolina.

HBI, based in Winston-Salem, North Carolina, is a leading marketer of everyday apparel under some of the world’s strongest apparel brands in the Americas, Asia and Europe. HBI wanted a secure, energy-efficient, robust and low-maintenance lighting design.


HBI worked with our team and Greg Mulholland, PE, President of Preferred Engineering, PLLC. We developed a plan to address HBI concerns and provide conceptual drawings and documents. Eventually, we designed two HID and six LED options for evaluation.

HBI chose one of the LED options. The LED lighting and control system for the Rural Hall facility was designed and installed with high-efficiency Lithonia fixtures controlled with smart photo and motion sensors. House side shields were also installed to mitigate light pollution.

This system and design utilized DLC-recognized products and was approved by Duke Energy for their custom rebate program. The project was bid to over 16 electrical contractors, and Reynolda Electric was the successful contractor bid on this project and worked with us, the local Lithonia representative and Mulholland to assist in value engineering the final installation.


The Lithonia fixture was a 416-watt replacement for a 1,000-watt fixture. Controls included DTL Part Night Dusk to Dawn Photo Sensor and SensorSwitch Motion Sensors. The manufacturer was Acuity Brands.


This system has been well received. HBI, with our assistance in filing, received a substantial Duke Energy rebate. The traditional type of system that would have been installed, HID, was calculated to cost $24,497 per year in energy — compared to $6,664 for the Lithonia LED system. The annual savings of the LED product are $18,833. The light quality in the parking lot was dramatically increased and created a much safer environment.