Centerline Windsor's Advanced LED Lighting Transformation

The four-building lighting renovation doubled visibility, reduced energy waste, and strengthened Centerline Windsor’s commitment to innovation and sustainability.

For nearly 70 years, Centerline Windsor, Ltd. has been one of Canada’s most-respected advanced automation manufacturing companies in the OEM space. Founded in 1957 by the Beneteau family, Centerline has grown from a single shop into an international enterprise with 800+ employees and four large buildings.

Like any long-running facility, Centerline eventually reached a point where the lighting system needed to evolve. For Centerline, that moment arrived when the company’s aging Philips FBX20 linear high bays, which were installed in 2009, finally reached the end of their useful life. The light levels had dropped, maintenance was constant, and despite repeated cleaning efforts, the fixtures simply could not support the visual demands of modern CNC machining, precision welding, and robotic assembly.

Centerline partnered with Wesco and LEDVANCE to modernize lighting across all four buildings in order to dramatically improve light quality, unlock major energy savings, and reinforce the company’s commitment to technological leadership and sustainability.

Assessing the project

Walking through Centerline’s facilities feels like a behind-the-scenes episode of How It’s Made with sparks from robotic weld cells, high-precision machining centers, and automated assembly lines performing complex technical operations. Their machinery has even appeared in scenes of Mission Impossible, underscoring their engineering innovation through large-scale robotic systems and advanced engineering capabilities.

In addition to staying ahead of technology trends, Centerline also pays attention to the working environment. Few people embody that dedication more than Jim Romanowski, Corporate Facilities Manager, who has been with Centerline for 34 years. Romanowski knows every building, every machine, and every fixture. Over the decades, he has led the company through multiple lighting transitions — from 400-watt metal halides to T5 fluorescents to the first generation of LED retrofits in 2009, and now to today’s advanced, sensor-integrated LED systems. And he’s continuously operated with one priority in mind: “I’m always looking for ways to save energy, costs and improve our facilities,” he says.

For Romanowski, staying ahead of each technological wave is essential to maintaining a world-class manufacturing environment. When he noticed increasing complaints about reduced visibility on the floor – especially from older machinists who struggled to read small engraved numbers or fine part details – he knew it was time for a change.

The challenge

By 2023–2024, the Philips FBX fixtures were showing their age. Light output had diminished significantly. Some fixtures were dirty or clouded from years of manufacturing by-products.

Others were failing outright, forcing frequent relamping and lift rentals. Dark spots had begun forming over key work areas, posing potential safety and accuracy issues.

Romanowski’s team took initial measures, including deep-cleaning hundreds of fixtures, which temporarily boosted light by 5 to 8 footcandles. But the reality was clear: the system was beyond its design life. The average measured illuminance sat at approximately 27 footcandles, far below what a modern facility of this caliber requires.

Energy waste was also escalating. The older LEDs ran continuously across all shifts — and without integrated controls, the entire shop remained fully lit even when sections were unoccupied.

“Before, at midnight, the entire shop was lit up. Now it doesn’t need to be,” Romanowski stated. For the four buildings on Morton Drive, Centerline needed a solution that improved visibility, enhanced safety, reduced operating hours, and aligned with the company’s long-term sustainability goals.

The solution

After evaluating several alternatives, Jim selected LEDVANCE LNHIBA6A High Bays with integrated PIR occupancy sensors. A total of 887 new smart high-bay fixtures were installed across the four buildings, replacing aging Philips FBX20 units one-for-one. In total, 887 new smart high bays were installed, delivering higher light output, better uniformity, and significant energy savings through automated dimming and shutoff in unoccupied zones.

A key partner in the solution was WESCO. Distributor partner Randy Lafreniere, Industrial Account Specialist at WESCO’s Windsor branch, supported the project from the earliest planning through delivery, ensuring product availability, coordinating timelines, and keeping all four buildings supplied with the correct quantities.

WESCO worked closely in tandem with LEDVANCE and Centerline to ensure all of the buildings were fully provided with the right quantities at the right time. Lafreniere’s involvement eliminated friction, prevented delays, and allowed Centerline’s maintenance team to proceed without interruption.

Romanowski’s decision came down to three factors:

1. Light Quality and Visual Precision

The new LEDVANCE high bays immediately doubled average light levels, raising the manufacturing floor from ~27 fc to ~62 fc. The 5000K CCT provided crisp, high-contrast visibility ideal for machining and inspection tasks.

2. Fully Integrated Occupancy Controls

Every fixture includes an onboard PIR sensor. After 30 minutes with no motion, the fixture dims to 50 percent. After an additional 15 minutes, it reduces further or turns off. Romanowski joked that the system effectively turned “each high bay into a smart light.” For the first time in years, the facility had an automated lighting strategy without costly wiring, empowering the facility with a retrofit that finally gave him and his team the controls they had always wanted.

3. Trust in the Brand

Having worked with LEDVANCE and SYLVANIA products for decades, Romanowski felt confident in the reliability and longevity of LEDVANCE’s high bays. “I really like the products – the features, the versatility, the quality. We trust the brand; their solutions deliver,” he said.

The installation

One of the most impressive aspects of the project was that Centerline’s own maintenance team completed the entire installation in-house. Across four active manufacturing buildings – each with machining centers, robotics, welding lines, and full production schedules – the team coordinated fixture replacements zone-by-zone.

Fixtures arrived exactly when needed, existing wiring (such as twist-lock connectors and 208 V circuits) was reused, and downtime remained near zero. Programming the integrated sensors with their stand-alone controls and remotes was straightforward as well.

“We put them up, programmed them, and after a few, we had the hang of it,” Romanowski explained. What mattered most to him, though, was recognizing the people behind the work. “A big thanks to my team,” he said. “We’re a small group, but we didn’t shut down operations; we didn’t miss a beat. Our team made this happen, and I’m very proud of the work they did.”

The results

The transformation was immediate and dramatic:

• Light levels doubled, improving safety and accuracy for machinists, welders, and inspectors.

• Older employees who previously struggled to read small engravings reported a dramatic improvement in visibility.

• Energy savings rose sharply due to occupancy controls.

• Many areas now dim or turn off during low-activity periods, reducing unnecessary runtime by 75 to 80 percent overnight.

• Maintenance costs dropped significantly.

• The team eliminated frequent relamping, fixture cleaning cycles, and lift rentals.

• Centerline’s sustainability mission advanced.

• Freshly repainted walls increased reflectance, enhancing the overall effect.

Over the decades, Romanowski has delivered substantial energy and maintenance reductions through multiple lighting upgrades, and this latest retrofit continues that momentum.

Centerline’s leadership views this retrofit as part of its long-term strategy to reinvest in its facilities, support employee well-being, and maintain a world-class environment for precision manufacturing.

Romanowski is proud of the company’s commitment to lighting innovation and sustainability. “We’ve always followed the technology. We’ve saved money on wattage, installation time, and now sensors. I’m proud of our team, and we’re looking forward to doing even more with LEDVANCE,” he stated.

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