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info@led-shop.com.auClient: Distribution Warehouse, North Brisbane
Project: LED High Bay Lighting Upgrade
Date: April 2025
Objective: Replace outdated metal-halide fittings with high-efficiency LED lighting to improve visibility, reduce power consumption, and meet Australian warehouse lighting standards.
Background
The client operates a 5,000 m² warehouse with 10 m high ceilings, running continuous day and night shifts. The facility previously used 240 × 400W metal-halide high bay lights, which produced inconsistent light levels, long warm up times, and high maintenance costs. Many areas fell below recommended illumination standards, leading to safety concerns and reduced productivity.
The client approached LED EXPO Australia to design a modern, energy efficient solution that could deliver higher lux levels, eliminate dark zones, and reduce electricity costs.
Solution
Our team performed a site audit and lighting simulation, comparing required illumination levels across different warehouse zones based on AS/NZS lighting guidelines.
| Illuminance (lux) | Use of Space | Typical Application |
|---|---|---|
| 40 lux | Rarely visited spaces – movement and orientation only | Bulk storage or infrequently accessed areas |
| 80 lux | Intermittent use search and retrieval tasks | Loading bays or storage rooms |
| 160 lux | Continuously occupied coarse detail work | Rough stock check, label reading, packing of large items |
| 240 lux | Continuously occupied moderate detail work | Dispatch areas, general warehouse work |
| 400 lux | Moderately difficult fine inspection tasks | Machine work, goods inspection and sorting |
After assessing the workspace, we selected UFO 300W LED High Bay Lights (replacing the old 400W metal halide fittings). The new fixtures were designed to deliver average 240–300 lux across working areas, ensuring compliance and improving visibility in critical zones.
Key product features:
- 150 lm/W efficacy for maximum brightness and energy savings
- Instant start with no warm-up delay
- Aluminium body with superior heat dissipation
- 5-year warranty and 100,000 hour lifespan
Installation was carried out in stages (one aisle at a time) to avoid disruption to operations.
Results
Energy Efficiency:
Power usage dropped by approximately 40%, thanks to the lower wattage and smart controls.
Improved Light Levels:
All work areas now meet or exceed the recommended 240 lux for general dispatch zones, and up to 400 lux in inspection areas. Workers reported noticeably clearer visibility and reduced eye strain.
Maintenance Savings:
No more frequent globe changes or ballast replacements LED lifespan ensures years of maintenance free operation.
Safety & Productivity:
Better visibility in picking aisles and loading bays led to fewer handling errors and a safer environment for forklift operators.
Pay-back Period:
Estimated at under 3 years, based on power and maintenance savings.
Client Feedback
“The new LED high bays completely changed the look and feel of our warehouse. We can see better, work faster, and our energy bill has dropped. The LED EXPO Australia team made the upgrade easy and professional from start to finish.”
— Operations Manager, Brisbane Distribution Centre
Key Takeaways
- LED retrofits deliver instant ROI through energy and maintenance savings.
- Correct lux level design ensures compliance and worker safety.
- Integrated controls (sensors and dimming) maximise efficiency.
- A tailored lighting plan can future-proof industrial spaces for years to come.
Thinking About Upgrading?
If your warehouse or factory is still using metal-halide or fluorescent fittings, you’re likely overspending on power and maintenance.
Contact LED EXPO Australia today for a free lighting audit and lux simulation we’ll design a system that pays for itself in savings while improving light quality and safety.