A 2010 McKinsey report forecasted the LED lighting marketing to be $69B in 2010. Honeywell was looking to enter the residential LED lighting market, targeting the hardware distribution channels. Honeywell looked to ITI as an OEM partner who could provide leading performance LED products, consumer insights, and marketing and product launch assistance.
ITI conducted market research and competitor analysis, focusing on key performance metrics and voice of the customer (VOC), to help Honeywell determine the requirements to launch a market-leading product. From our research, ITI provided to Honeywell 6 product SKUS that were differentiated models of ITIís LED bulb product line. ITI then managed the certification and multiple listing processes for UL, ETL, LM-79 and Energy Star. In addition, ITI used our consumer research and 25 years LED industry knowledge as guiding principles to help create Honeywell LEDís marketing materials: product packaging, brochures, fliers, and a versatile trade show booth. Furthermore, ITI advised on key marketing, product launch and consumer strategies; and sent personnel to attend shows as Honeywellís technical lead to answer customer questions.
Honeywell brought to market a full line of LED bulbs that led the category in energy efficiency. The Honeywell R30 is still considered to be Energy Starís most efficient BR/R30 LED bulb 3 years after its 2009 launch. Honeywell sold in and gained distribution at several hardware outlets, including Ace Hardware, True Value, Do it Best, Canadian Tire, etc. To date their best selling LED SKU is the BR/R30 3000K Dimmable bulb manufactured by ITI.
Combo exit emergency signs are large, bulky and unattractive when installed. The challenge was to create an exit sign that would disappear into its surroundings, but could still excel at showing inhabitants the path to safety in the event of a power outage or fire: how do you make something small and unnoticeable until, when needed, you can literally find it in a fire?
Innovation in product design comes not only from profound user insight and disciplined research, but a push to make things more sustainable and eco-friendly. Combo exit emergency signs are traditionally very heavy from the emergency batteries and are extremely bulky from the mandatory adjustable heads. In order to deliver a truly revolutionary product ITI knew our design must refine aesthetics while improving performance, and reduce both the product and carbon footprint.
Utilizing the superior benefits of the eDVA Tech LED, we designed a completely new, full LED circuit sign that reduced energy consumption to less than 1 watt, even during recharging.
The team really pushed the boundaries by using eDVA Tech LED in the emergency lights. Before ITIís innovative breakthrough, exit and emergency signs used higher energy consumption incandescent, halogen MR16s, or CFLs as the emergency light. Using eDVA Tech LED achieved:
Tongji University's 2009 Global Solar Decathalon team needed to create . They worked with ITI's product and lighting design teams to create a custom lighting solution for their solar powered home design using only LEDs. In addition, one of the greatest challenges of the project was that the Tongji team wanted to use fixtures that used omni-directional light.
The solar home design, which extended to the lighting products used, created a very livable and eco-friendly home based on key concepts derived from human-centric research.
ITIís lighting and design teams educated Tongji University's team on lighting design fundamentals and which LED product is most suitable for each application. ITI's team advised Tongji on how to configure the lighting to achieve the required illumination levels for tasks performed in the home. Lastly, ITI's team created a new series of LED bulbs which met both the omni-directional and illumination requriements in each application.
As a result, Tongjiís solar house had a lighting floor plan that consumed less than 140 watts in total. All LED products have a product life span of 50,000 hours or 50 times longer than incandescents and 6.25 times longer than CFL lamps. In addition, the house was able to save on average 80% over incandescent options and 60% over CFL options. Finally, using the eDVA Tech LED bulbs allowed the solar homes to eliminate mercury from their lighting, especially in key areas.
Old exit signs used to be powered by 2 incandescent lamps per sign, a stagant category with no innovation. The bulbs were inefficient in terms of both energy usage and maintenance. The bulbís 1000-hour life span meant bulbs were changed every 41 days. In addition, exit signs had strict illumination requirements to meet building and safety code visibility and signage stipulations.
After gathering legal requirements, customer needs, and conducting a competitor analysis the ITI team understood that the final products performance needed to be:
In addition, the product's design needed to encompass:
To create an innovative product that met regulatory, performance and customer needs ITI ended up pioneering the usage of LED as a replacement for incandescent bulbs. Using their proprietary eDVA Tech LED as the designís foundation, the team added advanced simplified circuitry to create the most efficient and long life light source available.
Next, the team tackled the challenges of even illumination and brightness. This is actually very difficult given the exit signís rectangular shape and double sided configuration. To compound the difficulty, the LEDís natural light pattern is 180 degrees, not the 360 degrees of an incandescent. ITIís solution created a unique paddle shape with each LED strategically angled to provide maximum light output and even letter illumination on both the front and back exit sign panels.
Lastly, to ensure ITI met the customerís requirement of easy installation, we implemented two systems. First, we included 2 extra adapters in every replacement kit to ensure our LED lamps fit into every type of exit sign socket. Second, we made the lamp base adjustable so the lamps are always parallel to the EXIT letters for maximum light output, regardless of how the customer screws in the bulb.
Since 2012, ITI has sold over 11M exit of its retrofit units. Each LED bulb saves 24 watts, helping ITI save over 262M watts of power and $29M USD in electricity costs.
The customer asked ITI to develop a white light, high-brightness, but also lightweight, low-wattage, dimmable, and waterproof LED bulb for use in the highly caustic, ammonia laden chicken-coop environment. To those familiar with the LED industry in 2010, you realize that the customer has asked for the seemingly impossible: a high brightness, white light, LED bulb required a larger heat sink, which directly negatively impacted the bulbís weight. A waterproof bulb eliminated the possibility of ventilation holes, a common industry practice to dissipate the heat generated from LEDs. As waterproof was a non-negotiable requirement (the bulbs needed to be pressure washed between chicken growth cycles), an innovative solution was required. Finally, the lower a bulbís wattage the more compatibility issues arose with existing dimmers, which of course, the customer did not want to replace.
After multiple tours to fully understand the chicken coop environment, light output requirements, and customer usage behavior, our team was ready to tackle the challenge. From the specifications, it was clear that the design needed to minimize wattage consumption to reduce heat production and eliminate ventilation holes. After developing and refining the initial concept, the team made prototype bulbs to evaluate our design. Next, ITI worked with the customer to set up test batches of 100 to 1000 bulbs per site to assess real world product performance. Afterwards, we pulled samples from each test site to evaluate product performance to gain learnings that improved our final product design. In addition, we managed the safety and environmental certifications for our client to obtain ETL and RoHS.
As with several previous projects, the eDVA Tech LEDís record breaking high-energy efficiency was the reason why ITIís design could meet the customer extensive list of requirements. eDVA Tech LEDís high efficiency created less heat per LED and solved the waterproof vs. heat dissipation issue encountered with other LEDs. Higher energy efficiency also meant a low wattage bulb without sacrificing brightness (enough to replace a 60W incandescent bulbís light levels). Furthermore, ITI developed a custom linear dimming circuit inside every bulb to meet the poultry growerís specific light output requirements at each phrase of the chickenís development while maximizing energy savings. The new circuit was also compatible with the customerís existing dimmers for a low-cost and easy conversion to LED. Finally, an added bonus was our productís 50,000 hours life rating (50 times greater than incumbent bulb) for dramatically reduced lighting maintenance cycles and labor costs.
Our customer had invented, patented, and bought to market an innovative emergency light. The fixture remains hidden during normal conditions and reveals itself during an emergency(ex. power outage or fire) to provide better safety lighting. The current fixture used high wattage xenon lamps, which required a substantial battery and additional optical system to function. ITI was tasked with improving on the already brilliant design and to replace the two 18W (36W total) xenon lamps with LED.
Critical to this project was the LEDís ability to match or exceed the xenon lampsí light output. Using rapid prototyping, the team mocked up a functioning LED replacement lamps and measured output. Light levels from both the xenon and LED lamps were compared on a 25ft x 25ft grid. The replacement LED met all light requirements in regard to both UL 924 and NFPA Life Safety Code 101 for the ďpath of egress.
Second, the ITI team looked to identify additional improvement areas. As the new LED replacement head would have significantly reduced the wattage requirements, the battery size and thereby entire unit size could be reduced. In addition, ITIís design for the LED replacement lamps eliminated the need for the additional optical system, which simplified assembly and reduced product costs to improve margin. The team presented their findings to the client.
ITIís recommended design for the new LED replacement lamp would have reduced the amount of batteries required, helping to decrease the unit's weight and material costs. The customer decided instead to keep the battery size the same and instead sell the new lamp design as providing up to 12 hours of emergency light, far exceeding the 90 min standard required by UL 924 and NFPA 101.
In addition, the new lamp design was able to increase illumination on the floor by an additional 10%, while eliminating the need for the additional optical system. The new design reduced wattage consumption from 36W to 3W, a savings of 91.7%.
Titan Atlas Manufacturing (TAM) wanted to provide off the gird, fully energy independent housing communities in developing countries. These communities, many aimed to be affordable for low-income owners, would exclusively use wind or solar energy. Therefore, each home in the community needed to minimize its energy footprint. In addition to the low energy required for this project, an additional challenge was the homesí construction method. TAM had designed a groundbreaking, exceptionally strong housing structure, with a build time of only 1 week. The homesí unique wall and roof structure, thinner than standard US homes, proposed a unique challenge if the housing developed wanted to use existing light fixtures. The roof was too thin for incumbent recessed cans, while using surface mounted ceiling lights cut into precious overhead space.
Relying on the teamís strong lighting design and human-centric research background, our designers used advanced light planning software and sophisticated ITI LED light distribution files(taken with our in-house goniphotometer) to carefully calculate and map out ideal lighting plans for each home based on family living habits. After analyzing our research data, the team defined the lighting requirements and brainstormed a list of possible fixtures. The team then carefully evaluated the beam angle and spacing options available with different fixtures to find a combination that minimized the wattage per sq. ft. while fulfilling light requirements.
After gaining a deep understanding of the familyís needs and TAMís construction requirements, our team curated the list of bulbs required for each of the 3 home layouts, while meeting or exceeding the Illumination Engineering Societyís (IES) light level recommendations for tasks (ex. cutting vegetables in the kitchen, reading in the living room, or applying make-up in the bathroom).
In the end, the team adapted 2 of ITIís existing products and created a brand new LED porch light. In most rooms, the team specified the D48 ceiling light, which provided ample light without intruding into the living space. However, in order for the D48ís to fit recessed into TAMís thin ceiling, ITI devised an entirely new j-box and mounting method. When designing the new j-box, ITI also created a new installation method that saved 5 minutes per installation, or 40 minutes per home.
Based on the most popular floor plan, an entire house consisting of 1 master bedroom, 2 bedrooms, 1 bathroom, a living room, kitchen and porch could be lit for fewer than 60 watts (equivalent to 1 standard incandescent bulb). The significant energy savings achieved by ITIís lighting design allowed TAM housing communities to meet their energy consumption constraints and lowered the amount of wind and/or solar generators required per community.