Replacing fluorescent lighting with LED in a commercial hall is done in a few clear steps: map out the existing situation, create a lighting plan, choose the right luminaires, have the installation carried out, and commission the system. The approach varies depending on the situation, depending on the type of hall, the current installation, and the requirements for light intensity and energy savings. In this article, you will get answers to the most frequently asked questions surrounding the transition from fluorescent to LED.
What costs are involved in switching from fluorescent to LED?
Three components determine your costs: the purchase of luminaires, the installation costs, and any engineering costs for a lighting plan. Depending on the size of the hall and the chosen type of luminaire, the investment costs vary, but in most cases, the transition pays for itself through energy savings and lower maintenance costs.
Industrial LED luminaires typically consume 50 to 70 percent less energy than comparable fluorescent systems. In addition, good quality LED luminaires last considerably longer, which significantly reduces the replacement frequency and associated labor costs. Especially in facilities with hard-to-reach installations, these maintenance savings are substantial.
What can further alleviate the investment: in the Netherlands, there is the possibility to make use of tax schemes such as the Energy Investment Allowance, which makes part of the investment costs tax-deductible. There are also subsidy options available for energy-saving measures in industry.
How do you create a lighting plan for an industrial hall?
Everything begins with a thorough inventory of the space: the dimensions, the working height, the activities that take place there, and the applicable standards for workplace lighting. Based on this, it is calculated how many light points are needed, at what height, and with what luminous intensity, in order to achieve an evenly distributed lighting level.
A good lighting plan takes the following elements into account:
- The desired illuminance in lux per work zone
- The light color (color temperature in Kelvin) suited to the activities
- The IP and IK classification of the luminaires, tailored to dust, moisture and mechanical stress
- The placement of luminaires for minimal glare and maximum uniformity
- Any emergency lighting and daylight control
Professional Lighting advice uses simulation software to precalculate the light distribution. This ensures that the new installation meets standards and provides the desired working conditions before a single luminaire is installed.
What is the difference between a retrofit and a complete luminaire replacement?
During a retrofit, the existing fluorescent luminaire is retained and only the light source is replaced with an LED equivalent. In a complete luminaire replacement, the entire luminaire, including the housing and optics, is replaced with a new LED luminaire. The difference lies in the depth of the intervention and the ultimate performance.
A retrofit is faster and cheaper to implement, but has limitations. The optical performance of the original luminaire remains a determining factor, which can limit light output and efficiency. Furthermore, the lifespan of the existing housing is an uncertain factor, especially in industrial environments with dust, vibrations, or moisture.
A complete luminaire replacement requires a higher initial investment, but typically delivers better lighting performance, higher energy savings, and a longer lifespan. In harsh industrial environments, this is almost always the wisest choice, because modern luminaires are designed with the proper IP ratings, thermal management, and optical systems specifically tailored to the application.
What steps are needed to replace fluorescent lighting with LED?
The TL to LED migration in a commercial hall is most effective via a structured step-by-step plan. By carefully going through each phase, you avoid technical problems, unexpected costs, and production downtime.
- Inventory: Map out the current situation. Note the number of luminaires, the type of fluorescent lamps, the mounting height, the room dimensions, and any special environmental factors such as dust, moisture, or heat.
- Drafting a lighting plan: Have a technical lighting plan created based on the standards for workplace lighting and the specific requirements of the hall.
- Luminaire selection Select LED luminaires that suit the environment, the required light intensity, and the IP and IK ratings that the situation demands.
- Tender process Request quotes from certified installers and compare not only on price, but also on warranty terms and the quality of the luminaires.
- Installation plan Coordinate the installation times with the company schedule to minimize disruption and production losses.
- Run installation: Have the replacement carried out by a certified installer, including the correct disposal of the old fluorescent lamps (which are considered chemical waste).
- Commissioning and control: Measure the lighting levels after installation and adjust any controls, such as sensors or daylight harvesting.
Which LED luminaires are suitable for heavy industrial environments?
Not every luminaire is designed for the conditions that heavy industry entails. Think of high or low temperatures, dust, moisture, vibrations, and sometimes also corrosive substances or explosion hazards. The minimum requirement is an IP65 rating for dust and water resistance, supplemented by an appropriate IK rating for mechanical protection.
In environments with extreme heat, such as steel mills or foundries, standard LED luminaires are inadequate. Luminaires specifically developed for high ambient temperatures and exposure to infrared radiation are needed here. Additional ATEX certifications apply to environments with aggressive chemicals or explosion risks.
For an overview of luminaires tailored to specific industrial applications,from workshop lighting to outdoor areas and climate chambers,it is worth looking at lighting for infra and terrain. Always consider the IP and IK ratings required by the environment during selection.
How long does the installation of LED lighting in a industrial hall take?
The installation duration depends on the size of the hall, the number of luminaires, the mounting height, and the complexity of the electrical installation. A smaller hall with dozens of luminaires can be completed in one working day, while large production sites require multiple days or weeks.
Factors affecting lead time include the accessibility of mounting points, the need for hoisting equipment or scaffolding, and the extent to which production can continue during the work. Phased installation, in which hall by hall or zone by zone is replaced, is a commonly used approach to limit downtime.
Good preparation, including a clear lighting plan and timely delivery of materials, yields the greatest time savings. When everything has been thought through in advance, the actual installation proceeds smoothly and predictably.
Practical example: Bokalift 2 – Crane vessel working lighting
A striking example of what the transition to LED looks like in practice is the project aboard the Bokalift 2, one of the largest crane vessels in the world. The technical challenges were considerable: the ship operates in harsh maritime conditions, with constant exposure to saltwater, severe vibrations from the crane, and extreme temperature fluctuations. Standard industrial luminaires would quickly fail under those conditions.
The design choices were therefore closely aligned with the operational limitations. Luminaires with a high IP rating and a robust IK value were chosen so that they are resistant to mechanical shocks and splashing water. Because maintenance at sea is costly and time-consuming, a long service life was central to the selection, replacements midway through an offshore operation are simply not an option.
What this project teaches is directly applicable to the transition from fluorescent to LED in industrial workshops: the environmental factors determine the choice of the luminaire, not the other way around. Anyone who determines the correct specifications in advance prevents expensive reinstallations afterwards. You can read more about this project on the page of the Bokalift 2 marine LED lighting project.
How JEL Products Helps with the Transition from Fluorescent to LED
JEL Products guides industrial organizations through the entire process of replacing fluorescent lighting with LED, from the initial analysis through to commissioning. The approach is tailored to environments where standard solutions fall short and reliability is non-negotiable.
What JEL Products specifically offers:
- Technical lighting advice and custom lighting plans for industrial buildings and sites
- High-quality LED luminaires under the DCbright and DarkLicht brands, designed and manufactured in the Netherlands
- Valves for extreme conditions: high temperatures, corrosion, ATEX zones, and environmental chambers
- Guidance on subsidy processes and tax schemes
- Complete peace of mind: from engineering and light poles to installation and maintenance
- ISO 9001 and VCA certified, with demonstrable experience in heavy industrial projects
Whether it is a single production hall or a large-scale project in the port and terminal sector, JEL Products works with you every step of the way. Feel free to contact us via the contact page for a no-obligation consultation about the possibilities for your situation.