First Year Energy Savings:
$39K+5 Year Return on Investment:
284%The Backstory
Tatsumi Intermodal U.S.A. Inc. faced challenges with consistent and effective lighting throughout its warehouse areas. They were operating with a legacy fluorescent lighting system that consumed excess energy while producing minimal brightness. Tatsumi approached LED Lighting Supply to provide a custom-tailored lighting solution that aligns with OSHA (Occupational Safety and Health Administration) requirements.
The Customer’s Challenge
The facility consists of three separate warehouse spaces with 300 fluorescent fixtures. Each section required a lighting solution that would increase overall brightness levels to meet OSHA illumination standards while preserving the existing wiring system. The fluorescent lights were only producing about 20 foot candles (fc) across each warehouse floor section. Proper lighting levels for a warehouse environment typically fall between 40 and 60 fc, depending on the space dimensions.
The Legacy Lighting System Posed Several Risks
- High heat output, increasing overall energy consumption and costs
- Uneven light levels creating blind spots, hot spots, and glare, which affect worker comfort and productivity
- Short fixture lifespan, causing frequent maintenance or replacement costs
- Potential non-compliance with OSHA workplace brightness standards
The Strategy & Solution
LED Lighting Supply’s Product Specialist, Joe Hawkins, consulted with warehouse manager Bruce Nguyen to understand project requirements. Instead of a typical one-for-one replacement, the solution included a single LED fixture replacing two of the existing fluorescent units.
Considering the mounting height (22 feet), wiring details (480v power cable, rod-mounted), space dimensions (Warehouse 1: 320 x 250 ft, Warehouse 2: 320 x 200 ft, Warehouse 3: 320 x 250 ft), and the desired foot candle levels (average 40 fc), a custom lighting plan was developed. The plan included rendered light levels, fixture layout recommendations, and product suggestions from our expert team.
The upgrade involved replacing the existing fixtures with wattage-adjustable linear high bay lights, using one new fixture for every two fluorescent units. In total, 300 old fixtures were removed, and 188 new fixtures were installed. This approach allowed the facility to retain existing wiring while providing brighter, more uniform illumination and significantly reducing energy consumption.
The Results
Post-upgrade foot-candle results:
- Warehouse Space 1: 47 fc average
- Warehouse Space 2: 41 fc average
- Warehouse Space 3: 47 fc average
These results confirm uniform light distribution throughout the space, meeting and exceeding OSHA requirements. Balanced illumination enhances operations, improves safety for forklifts and workers, and eliminates hotspots or dim areas.
Switching to LED lights reduced energy consumption by 47%, saving the warehouse approximately $39,190 annually. Over five years, the total projected savings are $144,950. The new fixtures last up to 50,000 hours, over three times the lifespan of the old 15,000-hour lights, while providing OSHA-compliant illumination.
| In 1 Year | In 5 Years |
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Key Benefits of Upgrading to LED High Bay Fixtures
- Over $39K in savings within the first year
- Over $144K in savings over five years
- Tripled fixture lifespan from 15,000 to 50,000 hours
- Fewer fixtures required while doubling light levels
This case study demonstrates how strategic planning and LED technology can transform an outdated lighting system into a more efficient, cost-effective solution. By taking a consultative approach and creating a customized lighting plan, LED Lighting Supply delivered a solution tailored to the warehouse’s specific needs, achieving required illumination levels with fewer fixtures and maximizing energy savings.
Direct Customer Feedback
Warehouse Manager Bruce Nguyen shared his experience via Trustpilot: “I wanted to share how impressed I am with your employees. They were incredibly patient and understanding throughout my warehouse lighting project. Because of their expertise, I felt completely comfortable moving forward with an order of 190 LED fixtures. They also went above and beyond to help me replace four defective units quickly. Thank you for the wonderful support!”
Tatsumi Intermodal U.S.A. Inc. continues to see positive results from its work with LED Lighting Supply, particularly in operational performance, worker safety, energy efficiency, and cost management. This case highlights the value of a well-planned lighting solution for warehouse environments.
