LED Lighting Upgrade Provides Frito-Lay Manufacturing Plant Energy and Maintenance Savings

Frito-Lay North America

Frito-Lay North America is a $29 billion convenient food business that makes some of the world’s most recognizable snack food brands. The company wanted to undertake a lighting project that provided energy savings and long-term maintenance savings for its Modesto, California manufacturing plant. Frito-Lay regards Chateau Energy Solutions as their long-term energy efficiency partner and entrusted them to design, develop, install, and manage rebates for the LED lighting retrofit.

Having been a partner of Frito-Lay for nearly 20 years, the team at Chateau Energy Solutions understood the complexity of the demanding environment within a food manufacturing plant. Not only did the lighting retrofit need to meet the strict food plant standards, but also the implementation of the retrofit needed to work around the challenging 24/7 food production schedule. Furthermore, Chateau leveraged the EPAct 179D federal tax deduction and ensured the lighting sensor and control technology were compliant with the stringent California Title 24 regulations.

Chateau Energy Solutions replaced and upgraded more than 2,760 fixtures with LED technology. The complete LED lighting project included both interior and exterior areas of the plant and all lighting products are backed with a 10-year warranty. The LED lighting upgrade saved Frito-Lay more than $201,000 annually, decreasing energy consumption by 1.5 million+ kWh per year, with a 3.1 year payback. This significantly reduced Frito-Lay’s CO2 emissions and improved the Modesto plant’s environmental impact.

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