With smart lighting, you can typically save between 50% and 75% on lighting costs in a warehouse compared to conventional systems. This is possible by combining LED technology with occupancy sensing, daylight control, and a smart control system such as DALI. The savings are greatest in warehouses with fluctuating occupancy, high ceilings, and sufficient natural light. In this article, we answer the most frequently asked questions about energy savings with smart LED lighting in a warehouse.
How much energy does lighting consume in a typical warehouse?
For many people, that doesn’t seem like much,until they see the bill. In a typical warehouse, lighting accounts for 30% to 50% of total electricity consumption. In warehouses with conventional fluorescent lighting that is left on continuously, this percentage is even higher. The exact energy costs depend on the floor area, the installation height, the number of operating hours per year, and the type of luminaire.
Take a 5,000 m² warehouse with outdated fluorescent lighting: that easily consumes tens of thousands of kilowatt-hours per year for lighting alone. At an average energy price of about 0.28 euros per kWh, those costs quickly add up to a substantial amount. In addition, conventional light sources convert a large part of their energy into heat instead of light, which also places an extra load on the building's cooling.
The transition to LED lighting in a warehouse is therefore the first and most impactful step. LED luminaires consume up to 60% less energy than traditional fluorescent systems while providing a comparable light level. If you then add smart controls, the lighting energy costs even further.
What is the difference between presence detection and motion sensors?
In practice, this distinction regularly causes confusion. Presence detection registers whether someone is present in a room, even if they are standing still. Motion sensors only detect active movement and turn off the light as soon as no more movement is detectable. For warehouse lighting, presence detection is the better choice in most cases.
The difference in daily practice is significant. A warehouse worker who stands still to operate an order picker or check a document falls outside the range of a standard motion sensor. The light then turns off incorrectly, which can create dangerous situations. Presence detection uses passive infrared (PIR) or ultrasonic technology to also register static presence.
For the industrial lighting control do the following rules of thumb apply:
- Motion sensors are suitable for passageways, emergency exits and areas with a short occupancy time
- Presence Detection is better for workstations, loading bays, and picking zones where employees work in one place for longer periods of time
- Combinations both techniques are possible via a smart control system
- Always set a switch-off delay of at least 5 to 10 minutes to prevent unwanted switching off
Both types of sensors contribute to energy saving of lighting in a warehouse because the lights are only on when needed. In a warehouse with an average occupancy rate, this can result in additional savings of 20% to 30% on top of the savings from LED lighting alone.
How does daylight control work in a warehouse?
Daylight control measures the amount of natural light in a room using light sensors and automatically adjusts the artificial lighting so that the total light level remains constant. The more daylight that enters through windows or skylights, the lower the power output of the luminaires. This is also known as daylight-dependent dimming.
In a warehouse with daylight openings or transparent roof panels, daylight control can make a significant contribution to lighting energy saving. On sunny days in the summer, the power of the luminaires near windows or skylights can already be halved while the light level for employees remains the same.
The installation requires light sensors placed at the correct height, preferably in the task area and not directly near the light sources. Proper calibration is essential: the sensor must measure the ambient light, not the light from the luminaires themselves. Daylight harvesting works best in combination with dimmable LED luminaires and a central control system such as DALI.
Do you want to know if your warehouse is suitable for daylight control? Via professional lighting advice you gain insight into the possibilities for your specific situation.
When is a DALI system the right choice for warehouse lighting?
A DALI system (Digital Addressable Lighting Interface) is the right choice when you want to individually control, dim, and monitor individual luminaires or zones via a single central platform. DALI is particularly suitable for larger warehouses, complex layouts, and situations where energy monitoring or integration with a building management system (BMS) is desired.
DALI distinguishes itself from simpler on/off systems by giving each luminaire its own digital address. This makes it possible to:
- Flexibly configurable zones that can be adjusted without changing wiring
- Individual luminaires dimmable based on occupancy or daylight
- Monitor and report energy consumption per zone or luminaire
- To automatically detect and report malfunctions
- Lighting scenarios to be set for day, night and weekends
For smaller warehouses or simple installations, a DALI system can be too heavy of an investment. In that case, simple PIR switches with a dimming function already provide a good foundation for warehouse lighting energy saving. The larger the warehouse, the more complex the layout, or the more frequently the use changes, the greater the added value of DALI. Also check the possibilities for Energy investment tax credit when purchasing a DALI system, as such investments in many cases qualify for tax benefits.
How much energy do you save with smart lighting in practice?
Numbers are nice, but what are the actual benefits? In practice, the combination of LED luminaires, occupancy sensors, and daylight control results in total energy savings of 60% to 80% compared to an outdated fluorescent lighting system without controls. The exact savings depend on the initial conditions, the warehouse’s usage, and the quality of the installation.
A realistic assessment per measure looks as follows:
- Replacing Fluorescent Lights with LEDs: 40% to 60%,Savings on Base Power Consumption
- Occupancy Detection: 20% to 35% additional savings based on periods of non-occupancy
- Daylight control: 10% to 25%,additional savings depending on the amount of natural light
- Schedules and Night Mode: 5% to 15%,additional savings for 24/7 operations
The payback period of a complete smart lighting installation in warehouses is typically between 2 and 5 years, depending on energy prices and the number of operating hours per year. For warehouses that operate day and night, the payback period is the shortest. More insight into the lighting technology behind these savings can be found on the page about lighting expertise.
What are the most common mistakes when installing smart lighting systems?
Even well-intentioned investments can fall short if the execution is not right. The most common mistakes are incorrect sensor placement, improper settings of the switch-off delay, and the use of incompatible components. These mistakes lead to dissatisfied users, safety risks, and significantly lower energy savings than expected.
Other common pitfalls include:
- Placing sensors near heat sources or air currents, causing them to trigger false alarms
- Ignoring the detection angle in high bay warehouses with view-blocking racking
- Calibrating daylight control on a cloudy day, causing the system to dim structurally too high
- Installing a DALI system without properly planning the zones in advance, which requires expensive adjustments later
- Cutting back on commissioning, meaning the system never functions optimally
Good preparation starts with a thorough lighting design that takes into account the warehouse layout, walking routes, rack height, and daily use. Always have sensors configured by a specialist and test the system extensively before the installation is handed over.
Case Study: DFDS Terminal Lighting in Vlaardingen
A concrete example of how well-considered lighting choices make a difference is the project at DFDS Seaways in Vlaardingen. For this terminal operator, everything revolved around the lighting of a large outdoor operational environment, with strict requirements in terms of reliability, energy performance, and ease of maintenance.
The technical challenge lay in the combination of an intensive usage pattern,the terminal operates almost continuously,and exposure to salt, moisture, and fluctuating temperatures. Conventional luminaires did not reach their expected lifespan, resulting in high maintenance costs and unwanted downtime at critical moments.
The chosen solution combined robust LED luminaires with a high IP rating and a control strategy closely aligned with the terminal's operational cycles. Zones with varying activity were equipped with presence detection, while critical passageways and loading docks remained illuminated at a baseline level at all times. This prevented unsafe situations while simultaneously ensuring a measurable reduction in energy consumption.
The lesson learned that is directly applicable to warehouse lighting: a smart system only works optimally if the control strategy matches the actual usage pattern. Generic settings are not sufficient, customization in zoning and sensor placement determines the ultimate result. More of these types of applications can be found at the project page of DFDS Seaways.
How JEL Products Helps with Smart Lighting in a Warehouse
Whether you’re setting up a new warehouse or looking to make an existing facility more sustainable, JEL Products provides support throughout the entire process,from the initial consultation to completion and ongoing maintenance. Specifically, you can count on:
- High-quality LED luminaires suitable for industrial environments, including dust, moisture and vibrations
- Custom lighting design, tailored to the layout and use of your warehouse
- Advice on the right control strategy: from simple PIR switches to complete DALI integration
- Guidance on subsidy schemes and tax regulations such as the energy investment tax credit
- Installation, commissioning, and maintenance by certified specialists (ISO9001 and VCA**)
Do you have a specific question or do you want to know what smart lighting can do for your warehouse? Feel free to take contact us for a no-obligation consultation.