Electrical improvements for food production and distribution
LH Block Electric completed warehouse lighting and facility electrical improvements at Garrett Popcorn’s manufacturing and distribution facility in Aurora, Illinois, working with general contractor DCS Midwest.
The broader renovation adapted an existing 140,000-square-foot building for food processing, mixing, packaging, and shipping, along with updated employee and office spaces. LH Block’s scope included LED warehouse lighting, advanced network lighting controls, emergency lighting, and electrical connections for refrigeration and production equipment.
Warehouse lighting built around the new racking layout
The new storage-racking layout required lighting positioned to serve the newly defined aisles and work areas. Our electricians installed 151 LED high-bay fixtures, each equipped with an advanced network lighting control sensor, to suit that arrangement.
Approximately 4,500 feet of new conduit and wiring extended existing 277-volt circuits to the required fixture locations. The racking layout also guided emergency-lighting and exit-sign placement: the original warehouse scope included 58 battery-backup emergency lights and 28 steel exit signs, with selected fixtures suspended approximately 20 feet above the floor to serve aisles and exit routes.
ComEd incentives for the lighting upgrade
LH Block worked with the ComEd incentive program to help Garrett Popcorn secure incentives for the facility’s lighting improvements. Alongside the fixture installation and network lighting controls, this assistance helped the customer make use of available financial support for the upgrade.
For owners planning a lighting upgrade, identifying applicable incentive opportunities is an important part of evaluating the project. LH Block can assist with that process; eligibility and incentive amounts depend on the project and program approval.
Emergency lighting throughout the facility
Beyond the warehouse scope, LH Block installed, replaced, and relocated emergency lights and exit signs throughout production areas, offices, hallways, and cooler spaces. This work included circuit adjustments and additional fixtures requested during the occupancy inspection process.
Refrigeration, production, and supporting equipment power
Walk-in cooler electrical installation
Our team connected the cooler condenser, three evaporators, condensate pump, and thermostat display. We also installed six owner-provided LED fixtures with door-activated controls and two cold-rated battery-backup emergency lights.
Production and packaging equipment
Electrical power connections served conveyors, a shrink tunnel, a wrapping machine, and a butter melter. The butter-melter installation included a dedicated 480-volt, three-phase circuit and fused disconnect.
Office and supporting facility power
LH Block connected 25 furniture receptacles serving workstations and conference tables, along with additional receptacles for office equipment and power for wall-mounted insect-control lights.
Ongoing electrical support directly for Garrett
Following completion of our work with DCS Midwest, LH Block continued working directly with Garrett Popcorn on additional projects throughout the Aurora facility.
As production areas are reconfigured and new equipment is introduced, we provide equipment power connections, circuit additions, and related electrical modifications. Familiarity with the facility’s electrical systems helps our team support Garrett’s changing production and operational needs.
Lighting and power that support an evolving facility
The initial installation aligned warehouse lighting with the new storage-racking layout, expanded emergency-lighting coverage, and supplied electrical connections for refrigeration, production, packaging, and office functions.
Our continued relationship with Garrett Popcorn extends that work as equipment, layouts, and operations evolve.