The Challenge
A 5,000 m² distribution center in Southeast Asia was still running 400W metal-halide high bays. The operator wanted lower energy bills, better light uniformity and a fast payback - without shutting down operations.
The Solution
We replaced 480 metal-halide fixtures with 480 HL-UFO-150W LED high bays at 160 lm/W, using 90° reflectors at a 9 m mounting height. Motion sensors were added in low-traffic zones.
Results
- Lighting energy consumption cut by 62%;
- Average illuminance improved from 180 lux to 290 lux;
- Uniformity improved from 8:1 to under 4:1;
- Estimated payback period: 14 months;
- Worker feedback: noticeably brighter aisles with less glare.
"The retrofit paid for itself faster than we expected, and the warehouse feels completely different at night." - Plant Manager
Why It Worked
Correct lumen targeting (beam angle + mounting height), high-efficiency modules, and simple motion controls delivered results without over-specifying wattage. A lighting audit before ordering is the single most important step.
Want a similar lighting audit for your facility? Contact our engineers.
