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INDUSTRIAL SECTOR

Warehouse &
Industrial LED

High-bay LED retrofits for distribution centers, manufacturing plants, and logistics facilities. AGi32 photometric design for every ceiling height. OSHA-compliant foot-candle targets. Minimal operational disruption.

SCHEDULE FACILITY AUDIT
75%
MAX ENERGY REDUCTION
70ft
CEILING HEIGHTS COVERED
24/7
OPERATIONAL ENVIRONMENTS
THE CHALLENGE

Lighting Is One of the Biggest Costs in Any Warehouse.

Large industrial facilities running legacy metal halide, fluorescent, or high-pressure sodium fixtures can spend 50–75% of their electricity budget on lighting. These systems run long hours, burn high wattages, and require constant maintenance — restrike times, frequent lamp failures, and expensive lift work to replace fixtures at height.

LED technology changes the economics entirely. High-bay LED fixtures consume up to 75% less energy, last 50,000+ hours, and provide immediate full-brightness output with no warm-up time.

  • Metal halide → LED: up to 75% energy reduction
  • Fluorescent T8 → LED: up to 50% energy reduction
  • 50,000+ hour rated life — dramatically reduced maintenance
  • Instant-on, no restrike delay between startup and full output
  • Improved uniformity reduces dark aisles and safety risks
TYPICAL MH TO LED REDUCTION
75%
Energy savings for metal halide replacement
CEILING HEIGHT COVERAGE

Engineered to Your Ceiling Height

Not every warehouse is the same. Our photometric engineers design around your actual facility dimensions — not generic recommendations.

15–25FT

Low Bay

Linear LED and low-bay UFO designs for rack areas and mezzanine levels. High uniformity, minimal shadows between rack bays.

25–45FT

Mid Bay

UFO high-bay and linear high-bay LED for the most common warehouse ceiling heights. Optimized beam angles for aisle and cross-aisle coverage.

45–70FT

High Bay

High-output LED fixtures rated for extreme heights. Engineered beam angles to maintain foot-candle targets at floor level despite increased mounting height.

DESIGN PROCESS

AGi32 Photometric Modeling on Every Project

We use AGi32 — the industry standard photometric calculation software — to model every warehouse retrofit before a single fixture is ordered. You see the foot-candle distribution, uniformity ratios, and layout on paper before installation day.

  • OSHA 1926.56 and IES RP-2 compliance verification
  • Foot-candle heat maps showing exact coverage before install
  • Uniformity ratio analysis per zone
  • Emergency egress lighting integration
  • As-built layout provided after commissioning
OSHA MINIMUM — GENERAL WAREHOUSING
10fc
We typically target 20–30fc for operational areas
ADD CONTROLS — PUSH SAVINGS TO 80%

Occupancy Controls for Warehouses

Aisles go unoccupied for significant portions of any shift. High-low dimming brings fixtures to 20–30% output when no motion is detected, then steps back to 100% within seconds of occupancy — saving an additional 25–35% on top of base LED performance.

  • Aisle-level occupancy sensors for rack and pick areas
  • High-low dimming — 100% occupied / 20–30% vacant
  • Dock door sensors — full output only when door is active
  • All controls rebate-eligible alongside LED fixtures
EXPLORE LIGHTING CONTROLS
WITH CONTROLS ADDED
80%
Total energy reduction vs legacy metal halide
CLIENT RESULTS
"Echelon retrofitted our 280,000 sq ft distribution center in three weeks. We saw a 63% reduction in lighting costs from month one — and the crew was immaculate."
MARK T. — DIRECTOR OF OPERATIONS, REGIONAL LOGISTICS CO. · 280,000 SQ FT DISTRIBUTION CENTER
COMMON QUESTIONS
Can the retrofit be done without shutting down operations?
Yes. We work zone-by-zone — typically one or two aisles at a time — so the rest of the facility remains operational. We schedule work around your shifts and can work nights or weekends for 24/7 facilities.
Do LED high-bays work with existing fixtures or do I need new ones?
For metal halide and HPS high-bays, we typically recommend full fixture replacement because the old housings aren't designed for LED thermal management. For fluorescent troffers in office and dock areas, a direct retrofit kit often works. We specify the right approach per zone during the audit.
Are there rebates available for warehouse LED projects?
Yes — industrial projects often qualify for the largest rebate amounts because of high fixture counts and significant wattage reductions. We handle all rebate identification, pre-approval, and submission. See our rebates page for details.
Cut your warehouse energy bill by up to 75%.
Free audit, AGi32 photometric design, and full rebate management included on every project.
SCHEDULE FACILITY AUDIT