Lighting Case Study: Warehouse Upgrade Results in Energy Savings Improvement of over $45K

The Backstory:

LED Lighting Supply was approached by LED Conversions, the contractor for this warehouse project, to support with a warehouse lighting upgrade. The existing lights in the facility included antiquated 400-watt metal-halide fixtures, which prevented achieving proper warehouse lighting levels, negatively impacted working conditions, and increased operational costs.

The Customer’s Challenge:

Operating with outdated metal halide fixtures in place created several challenges for the warehouse:

• High energy consumption, leading to increased utility costs
• Uneven light distribution, resulting in poor visibility across aisles and work areas
• Frequent maintenance and lamp replacements, increasing downtime and labor costs
• Inconsistent light quality, contributing to eye strain and reduced worker productivity

The Strategy & Solution:

After gathering project requirements, including mounting heights, area dimensions, and limitations, LED Lighting Supply developed a custom-tailored lighting plan for the space.

The plan detailed a rendering of the light distribution with the recommended metal halide replacement, demonstrating the improved light levels across the warehouse. Our Product Specialist recommended replacing the outdated light fixtures with 100/120/150/200 Watt Adjustable LED UFO High Bays. In total, 81 fixtures were replaced, providing an average foot candle (fc) reading of 55, which is more than sufficient for a warehouse environment.

The Results

Transitioning from legacy metal halides to high-performance LED fixtures increased the facility’s energy savings by 73%. With a 20-year life expectancy, the upgrade significantly reduces operational overhead. Over the next five years, the warehouse is projected to save $45,760 in energy costs and $1,215 in maintenance fees, all while providing a safer, brighter environment for employees.

Savings & Payback Overview

Key Project Milestones:

• 73% Reduction in lighting-related energy consumption
• $45K+ Project Savings realized within the first five years
• Elimination of Routine Maintenance: 20-year fixture life expectancy minimizes downtime
• Enhanced Safety: Uniform light distribution for a safer workspace

This project illustrates how strategic planning and high-efficiency LEDs transform outdated infrastructure into a cost-effective asset. By utilizing a consultative approach and custom photometric planning, LED Lighting Supply delivered a solution perfectly aligned with the facility's specific requirements.