Real Case: How We Lit a 3,000 m² Logistics Warehouse with LED UFO High Bay Lights and the Results

A year ago, the operations manager of a food distribution company in Toledo made an important decision. He had spent three years thinking about changing his warehouse's lighting. The investment seemed high to him and he never quite got round to taking the step.

This is the real LED warehouse lighting case that convinced him. It's a 3,000 square metre warehouse with the same problems that many industrial warehouses still carry today. Here's the full process, with verifiable figures, to calculate your own savings before looking for an LED lighting quote for a logistics warehouse.

The starting point: our real LED warehouse lighting case with 20 years of metal halide

Initial diagnosis and problems detected

The warehouse had been running for twenty years with 400W metal halide floodlights. The lighting system showed a noticeable loss of luminous flux and several blown units that hadn't been replaced. The technical team measured the actual level on the floor and confirmed areas well below the lux illuminance level required by logistics activity.

Electricity consumption was high for two reasons. The installed power was high and the lighting ran continuously, typical of industrial environments with morning and afternoon shifts. The warehouse's high 8-metre ceilings also complicated any maintenance task and made every lamp replacement more expensive. The question the client was asking was simple: how to replace metal halide with LED in a warehouse without stopping activity or blowing the budget.

Project objectives efficiency savings and wellbeing

The client set three clear objectives for the turnkey lighting project he was looking for. The first, to improve energy efficiency without affecting the warehouse's daily activity. The second, to achieve measurable energy savings from the very first month of operation. The third, to improve the visual comfort of the operators working with forklifts and manual picking.

Making the switch to LED technology was also a way of modernising the whole warehouse for the future. These three objectives guided every technical decision in the project, from the lighting calculation to the final choice of luminaire.

Phase 1 - Calculating lighting requirements

Before choosing any luminaire, the team did the calculations that determine the whole project.

Recommended lux level for logistics according to the standard

The European standard EN 12464-1 sets recommended illuminance levels according to the type of activity in each area. Circulation aisles in logistics warehouses need a minimum of 100 to 150 lux. Picking and order preparation areas require between 200 and 300 lux.

The lux calculation for the industrial LED warehouse started from these values and cross-referenced them with the actual surface area of each work zone. The real goal went beyond the legal minimum. We were looking for a uniform level across the whole floor, with no dark areas between columns or in the narrowest aisles.

How we calculated the number and layout of high bay lights

The total warehouse power calculation started from three pieces of data. The 3,000 m² surface area, the warehouse's high bay mounting height, and the luminous flux of each candidate high bay light completed the equation.

With 8-metre ceilings, the team applied the warehouse's utilisation factor. This estimated how much usable light actually reaches the work plane, deducting losses from reflection and obstacles such as tall racking.

This calculation answered the question that comes up most often in similar projects: how many LED high bay lights do I need for a warehouse this size. The answer was a layout of high bay lights per surface area in a regular grid, spaced roughly every 6 metres. The final result was 60 LED high bay lights for an 8-metre-high warehouse, arranged in rows parallel to the main aisles.

Phase 2 - Product selection

With the calculations settled, it was time to decide which luminaire to install.

Why we chose 150W UFO high bay lights with Samsung chip

The team compared several manufacturers before settling on the 150W Samsung UFO high bay light for the warehouse as the final solution. The real LED UFO high bay light chosen for the logistics warehouse features a high-efficiency Samsung chip. Its luminous efficacy exceeds 150 lm/W, well ahead of the market average for an industrial LED high bay light.

This type of luminaire stands out for its price-to-performance ratio, with a lifespan of over 50,000 hours. We also chose a 5000K colour temperature. It renders colours better for picking and quality control tasks, and gives a whiter, crisper light than the old metal halides.

High-quality industrial LED lighting reduces consumption without sacrificing visual performance. This was something the client noticed from day one.

0-10V dimming driver for night-time reduction

Each high bay light incorporates a driver with 0-10V protocol. This driver allows a night-time driver dimming schedule to be programmed for the lowest-activity hours, usually between 10pm and 6am.

This adjustment cuts electricity spend by up to a further 30%, without switching the warehouse off completely. It's an essential function in a warehouse with rotating shifts and constant movement of goods.

Phase 3 - Installation without stopping operations

Installation was the most delicate point of the project, as the warehouse couldn't stop.

Zone-by-zone planning to avoid interrupting operations

The team divided the warehouse into four zones and worked at night on each one. It followed a step-by-step industrial LED high bay light installation protocol, designed not to affect daytime activity.

Each work shift replaced between 15 and 18 high bay lights. This was always done outside goods receiving and dispatch hours, when the type of activity with the most forklift traffic is concentrated.

Total installation time and resources required

The complete installation of the LED UFO industrial lighting project was finished in four nights of work. The team consisted of three electricians and one site supervisor.

There was no need to hire additional aerial platforms, as the warehouse already had an overhead crane. This sped up access to the high ceilings and cut the total expected time by a full day.

Results after 6 months of operation

Six months after finishing the installation, the figures speak for themselves.

Consumption before and after in monthly kWh

The electricity consumption data confirms what the initial calculation promised. The table summarises the full comparison between the old installation and the current one.

Energy consumption was cut by more than 70%. The average lux level on the floor, meanwhile, doubled.

That contrast, lower electricity consumption and more usable light, sums up well the LED UFO logistics warehouse savings the client had been looking for from the start.

Savings on maintenance and lamp replacement

Besides the electricity savings, the industrial LED maintenance plan drastically reduced technical visits. With the metal halides, the maintenance team replaced lamps every eight to ten months, with the added cost of hiring an aerial platform each time.

Maintenance costs dropped to almost zero during the first year. The lifespan of the new high bay lights covers several years of continuous operation, with no intervention needed.

ROI calculation and real payback time

With a known total investment and monthly savings of 4,200 euros, the return on investment for the industrial LED lighting came in at just over two years. That calculation includes both the electricity savings and the maintenance savings.

The payback on the industrial LED investment for this particular project was faster than expected. The client made the most of the lowest-activity hours to maximise the effect of the dimmable driver. After that period, every month of operation is net savings for the company.

What we took from the project what we'd repeat and what we'd do differently

This project leaves several lessons applicable to any practical LED logistics warehouse lighting case. We would certainly repeat the zone-by-zone prior calculation, as it avoided over-sizing the installation and matched the budget to actual needs. We would also repeat the phased night-time installation, which meant not stopping activity for a single shift.

What we'd do differently is bring up the conversation about night-time driver dimming from the very first contact. It's one of the savings levers that surprises clients most when they see the bill. This project shows that energy savings and the initial investment aren't at odds when the prior calculation is done properly.

Any maintenance manager who wants to efficiently light a similar warehouse can start from these same steps. Are you wondering how to light a 3000m2 warehouse with LED and guarantees. An industrial estate lighting project like this one is a good starting point for calculating your own case.

Have a similar warehouse? Here's how we can help

If you manage a warehouse with similar problems, you'll probably recognise yourself in several parts of this real LED warehouse lighting case. We work the same way with industrial warehouses for distribution, production or storage. We tailor every real warehouse lighting project to the specific surface area, height and activity of your facility.

You don't need to have all the technical data ready. The surface area, the height and a few photos of the interior are enough. Our team does the lighting calculation and sends you back a proposal with the number of high bay lights, total power and estimated savings. Request your free assessment and compare your current situation with the results you've just read.

Frequently asked questions about logistics warehouse lighting with LED UFO

How many LED high bay lights do I need for a 3,000 m² warehouse?

It depends on the height and the interior layout. As a reference, this warehouse has a 3,000 m² surface area and 8-metre ceilings. It needed 60 150W high bay lights to achieve a uniform lux level across the whole floor. In lower warehouses or with fewer obstacles, the number can vary.

What lux level is recommended in a logistics warehouse?

Circulation aisles usually need between 100 and 150 lux. Picking and quality control areas require between 200 and 300 lux, according to the EN 12464-1 standard. The goal is to avoid dark areas between racking.

Can it be installed without stopping the warehouse's activity?

Yes, it's common to plan the installation by zone and in night shifts, as was done in this project. The daily activity of receiving, picking and dispatch isn't interrupted at any point.

How long does it take to pay back the investment in LED UFO high bay lights?

In this case, payback was completed in just over two years, combining electricity savings and maintenance savings. The timeframe varies depending on daily hours of use and the contracted electricity tariff.

Do LED UFO high bay lights work well in warehouses with extreme temperatures?

Yes, industrial-range UFO high bay lights are designed to withstand wide temperature ranges. They work well in both cold storage warehouses and warehouses with heat build-up in summer. The heat sink and the driver are the key components for guaranteeing that resistance.

What high bay light power do I need for an 8-metre height?

For mounting heights close to 8 metres, power ratings of 150W to 200W are usually sufficient. It all depends on the lux level required by the activity. In this warehouse, 150W with a Samsung chip was the option that best balanced consumption and performance.