Rockline Industries Cuts Operating and Maintenance Costs with LED Lighting Upgrade

Rockline Industries, a global leader in premium paper products, has successfully cut operating and maintenance costs by upgrading its production lighting to high‑efficiency LED fixtures from Dialight.

As a major private‑label wet‑wipe supplier to Walmart, Rockline has long been committed to sustainability. The company’s “Changing Our Environmental Footprint” program targets a 2% reduction in energy use and greenhouse‑gas emissions per unit of production.

Gentle on skin, wallets, and the planet
For over 30 years, Rockline has supplied household paper and non‑woven products—including coffee filters, baking cups, baby wipes, and its newest biodegradable, flushable toilet tissue. All of its wet‑wipe lines are 100% biodegradable and made from 100% renewable resources.

Rockline’s sustainability strategy extends beyond product ingredients. The company is also modernizing its facilities to slash energy consumption and emissions.

Reducing energy costs in Booneville
The Booneville, Ark., plant used 15 metal halide fixtures (400 W each) for 12 h/day, five days a week, and 125 fixtures for 24 h/day in the manufacturing area. All 140 fixtures were replaced with Dialight’s DuroSite LED High‑Bay luminaires.

Each LED unit draws only 150 W—reducing energy per fixture by 250 W. Combined, the retrofit cuts annual energy use by roughly 35 kWh per fixture, saving the company thousands of dollars each year. The improved light output (11,600 lumens, 79 lm/W) also provides brighter, more uniform illumination.

“The installation went very smoothly with minimal interruption to our production line,” said Nick Santoleri, vice‑president of manufacturing. “Because the new fixtures use standard plugs, no rewiring was needed.”

Lower maintenance, lower costs
The old metal halide fixtures required lift rentals to service 18‑foot mounts, driving up maintenance costs. The new LED fixtures, with their long‑life Cree XLamp XP‑G LEDs and advanced thermal management, can last up to 10 years. Dialight covers the first five years under a no‑cost replacement warranty.

Additionally, the reduced heat output has lowered the plant’s HVAC demand by 20 tons—10–15%—which translates into further energy savings and a cooler working environment for employees.

“Employees notice the cooler temperature and appreciate the crisp, white light,” Santoleri added. “The LEDs are also instant‑on, which is critical during power outages caused by severe weather.”

Rebate program adds to the upside
Rockline has already secured a $48,000 energy‑savings rebate from American Electric Power’s Southwestern Electric Power Company for the LED retrofit. “The combined cost savings and rebate make LED lighting a cornerstone of our sustainability plan,” Santoleri said. “We’re already evaluating other areas—such as the building exterior and truck loading bay—where LED upgrades can further enhance safety, color rendering, and energy efficiency.”

For more information on Dialight products and services, visit www.dialight.com.