Dragon Dream Series LED High Bay Light |1200㎡ Logistics Warehouse Lighting Retrofit Project Case

 

Project Overview 

Project Name:12,000㎡ Large Logistics Warehouse Lighting Renovation Project in Northern Europe

Project Location: Northern Europe

End Customer: Local professional third-party logistics service provider

Adopted Products: HRLUX Dragon‑Dream Series LZMTPD-A / LZMTPD-B Industrial LED High Bay Lights

Site Conditions:10-meter-high ceiling, integrating high-level shelf storage aisles and open sorting operation areas, with complex and diverse lighting scenarios

Project Cycle:33 days in total, including 7 days of professional optical simulation and scheme design, and 26 days of on-site dismantling, installation, wiring and system debugging

Core Project Requirements

The customer’s warehouse had long adopted traditional metal halide lamps, which could no longer meet local industrial safety lighting specifications. The customer hoped to complete an efficient and low-cost lighting upgrade with the following core demands:

1.Eliminate outdated 400W metal halide lighting systems, fully comply with EN 12464 1 industrial lighting standards, and stabilize the average working illuminance of the whole warehouse above 180lx.

2.Optimize light distribution, eliminate local dark areas and glare problems, reduce visual fatigue of long shift operators, and improve overall warehouse operation safety.

3.Adapt to the dusty and humid indoor industrial environment, equipped with high standard dustproof and waterproof performance to ensure long-term stable operation of lamps.

4.Solve the pain points of high-power consumption and frequent high-altitude maintenance of traditional light sources, effectively reduce daily operation costs and achieve stable investment returns.

5.Reserve intelligent dimming expansion space, compatible with the original ceiling suspension structure, and minimize on-site transformation and capital investment.

Project Pain Points & Site Challenges

Before the renovation, the warehouse had prominent lighting defects, and the traditional lighting system could not match the high standard operation demand of modern logistics warehouses.

1.High energy consumption and fast light decay: The original 400W metal halide lamps consume huge power in long-term operation. After 8000 hours of use, the light attenuation is serious, resulting in dim overall light. Meanwhile, the lamps have slow startup and restart response, which cannot support efficient continuous operation.

2.Unqualified lighting effect: The original average illuminance of the site is only 112lx. The shelter of high-rise shelves forms a large number of shadow blind areas. The UGR glare value is higher than 28, which is easy to cause visual fatigue and cannot meet EU industrial safety lighting specifications.

3.Poor environmental adaptability: The warehouse is in a humid and dusty environment all year round. Most ordinary LED high bay lights on the market have false protection standards and insufficient heat dissipation capacity, which are prone to water inflow, dust accumulation and lamp damage, leading to frequent replacement.

4.Single lighting scheme cannot adapt to mixed scenarios: The alternating distribution of narrow shelf aisles and open sorting areas puts forward differentiated light distribution requirements. A single beam angle layout cannot take into account both antihadron lighting of narrow aisles and uniform lighting of large open spaces.

5.Limited renovation budget: The customer required to make full use of the original suspension lifting structure to avoid large-scale steel structure reconstruction and additional engineering costs.

Customized Lighting Solution

1. Design Standards & Product Selection

Combined with EN 12464-1 industrial lighting specifications and actual on-site environment, HRLUX technical team formulated targeted lighting design indicators, and selected matching products according to different functional areas of the warehouse:

 

Important Construction & Usage Notes:

- The reuse of original hanging accessories must be based on professional load-bearing inspection, and all unqualified aging parts need to be replaced as required.

- The 0-10V dimming function needs to match the on-site power distribution system, and intelligent debugging is carried out after confirming the circuit conditions.

- IP66 protection is suitable for indoor dust and splash water prevention, not applicable to fully open outdoor exposed installation scenarios.

- The final lighting effect is affected by on-site installation height and angle deviation, which needs professional calibration during construction.

Regional Matching Layout Scheme:

- Shelf Narrow Aisles: Adopt LZMTPD-B 150W high bay light with 60° narrow beam angle, which concentrates light vertically, effectively offsets the shadow occlusion of high-rise shelves, and ensures uniform light in the walking and picking area.

- Open Sorting Area: Adopt LZMTPD-A 200W high bay light with 120° wide beam angle, covering a larger horizontal area, realizing overall uniform lighting of the open operation space.

- All lamps adopt fully sealed industrial-grade structure, reserved intelligent dimming interface, which can be upgraded to centralized intelligent lighting system later.

 

2.Standard Implementation Process

HRLUX adopts a standardized one-stop engineering process from survey and design to final acceptance to ensure that the actual effect is highly consistent with the simulation scheme:

- On-site Precision Survey: Measure warehouse height, shelf spacing, lamp position distribution and original hanging point parameters, collect site CAD drawings, and sort out on-site transformation constraints.

- 3D Optical Simulation Design: Use Dialux EVO professional lighting software to build a 3D site model, simulate the light distribution effect of mixed beam angles, generate professional illuminance cloud map and lighting report.

- Scheme Optimization & Confirmation: Adjust lamp power and layout density according to simulation data, maximize the reuse of original facilities, and reduce transformation cost.

- Factory Precision Production & Inspection: Equipped with brand constant current drive, diamond heat dissipation structure and anti-glare lens, all lamps pass strict factory aging test.

- On-site Standard Construction: Complete old lamp removal, new lamp fixing, circuit sorting and light angle calibration in strict accordance with electrical construction specifications.

- Testing & Delivery: Conduct on-site illuminance and uniformity testing, sort out IES light distribution files, simulation reports and product certification documents for handover.

 

 

Core Product Advantages 

Compared with ordinary low-cost LED high bay lights on the market, HRLUX Dragon-Dream series industrial lamps have obvious comprehensive performance advantages, solving many pain points of traditional industrial lighting:

- Efficient Diamond Heat Dissipation Structure: The die-cast aluminum diamond cutting structure expands the heat dissipation area in all directions, quickly exports internal heat, effectively inhibits light decay, and ensures the L70 service life of more than 50,000 hours, avoiding the problem of rapid brightness attenuation of inferior lamps due to poor heat dissipation.

- Genuine IP66 Industrial Sealing: The fully integrated sealing process realizes dust tight and splash water resistance, which can operate stably for a long time in humid and dusty industrial scenarios, eliminating the false standard problem of ordinary lamps.

- Multi-Beam Angle Customization: Three beam angle options of 60°/90°/120° are available, which can flexibly adapt to narrow aisle anti-shadow lighting and large-space uniform lighting, realizing personalized matching of different scenarios.

- High-Quality Anti-Glare Optical Design: Equipped with professional optical lens and reflector, the UGR glare value is controlled below 22, which effectively protects the eyesight of long-hour operators and improves working comfort.

- Stable Wide-Voltage Operation: AC85-265V universal wide-voltage drive with built-in surge protection, which can resist complex grid voltage fluctuations and adapt to various industrial power environments, supporting 0-10V intelligent dimming.

- Diversified & Low-Cost Installation: Supporting hook and chain suspension dual installation methods, compatible with most of the original high-bay lamp hanging structures on the market, no need for large-scale steel structure modification, saving transformation time and cost.

Project Acceptance & Measurable Benefits 

1.On-Site Acceptance Data

After the completion of the renovation, the professional team conducted on-site lighting testing. All indicators fully meet and exceed the EU EN 12464-1 industrial lighting standards:

- Average maintained illuminance: 192lx

- Lighting uniformity Uo: 0.74

- UGR glare value: 21

- Color rendering index Ra: 82

- On-site effect: No obvious dark shadows in the shelf area, uniform light in the open operation area, and great improvement in visual comfort

2. Economic & Operational Benefits

This lighting renovation has brought dual improvements in energy-saving economy and operational safety, with obvious long-term value:

- Significant Energy Saving Effect: Replace high-power 400W metal halide lamps, the overall power consumption of the warehouse lighting system is reduced by 59%, with an annual electricity saving of about $14,820.

- Greatly Reduced Maintenance Costs: The modular high-reliability design avoids frequent lamp damage and replacement. The frequency of high-altitude maintenance operations is reduced by 76%, saving about $3,460 in annual maintenance costs.

- Short Investment Payback Cycle: The static investment payback period of the whole project is only 1.8 years, with high cost performance.

- Improved Operational Safety: Standardized lighting environment eliminates operational risks caused by insufficient light and glare, reducing manual operation errors.

- Long-Term Stable Value: With 5-year official warranty and super long service life, it effectively reduces the total operation and maintenance cost of the warehouse in the 10-year operation cycle.

Customer Testimonial 

efore determining the renovation scheme, we compared the solutions of three industrial lighting suppliers. Most manufacturers only provided lamps without professional lighting design services. HRLUX stood out with its one-stop service of Dialux simulation, personalized scheme customization and complete product supply.

After the installation of Dragon-Dream series high bay lights, the lighting problems of shelf shadows and uneven brightness in the warehouse have been completely solved. The actual lighting effect is highly consistent with the simulation data. The monthly power consumption is significantly reduced, and the later maintenance pressure is greatly reduced. We are very recognized for HRLUX’s professional capability and product quality, and will continue to cooperate in subsequent lighting upgrading projects.

— Facility Management Person in Charge, Northern European Logistics Warehouse

Project Summary

This 12,000㎡ logistics warehouse lighting renovation project fully verifies the excellent performance of HRLUX Dragon-Dream series LED high bay lights in modern industrial high-space lighting scenarios. Aiming at the mixed lighting pain points of high shelves and open areas in traditional warehouses, HRLUX adopts differentiated mixed beam angle layout, combined with IP66 industrial-grade reliable quality and professional Dialux optical simulation technology, to completely solve the problems of insufficient illuminance, serious shadows large glare, high energy consumption and difficult maintenance of traditional light sources.

The project fully embodies HRLUX’s comprehensive industrial lighting engineering strength of on-site survey, customized design, optical simulation, product supply, construction guidance and after-sales guarantee. It provides a highly replicable professional reference for lighting renovation and new construction of logistics warehouses, factory workshops, stadiums and other high-ceiling spaces.

Learn more about products: Dragon Dream Series LED High Bay Light

Frequently Asked Questions 

Q1: What kind of warehouse scenarios need mixed beam angle lighting layout?

A1: For warehouses with both dense high-rise shelf aisles and large-area open sorting and packing areas, a mixed layout of 60° narrow beam and 120° wide beam is recommended. Narrow beam concentrates light to eliminate shelf shadows, while wide beam ensures uniform lighting in open spaces.

Q2: Can Dragon-Dream high bay lights reuse the original warehouse hanging structure during renovation?

A2: Yes. The product supports standard hook and chain suspension. On the premise of passing professional load-bearing safety inspection, most of the original hanging accessories can be reused, effectively saving transformation cost and cycle.

Q3: What application environments are IP66 high bay lights suitable for?

A3: It is widely used in indoor industrial scenarios such as dusty warehouses, humid processing workshops and covered loading and unloading areas. It is not applicable to fully exposed outdoor environments without protective canopy.

Q4: What is the general investment return cycle of warehouse LED lighting renovation?

A4: The return cycle is affected by site height, daily lighting hours and local electricity price. For 24-hour operating large logistics warehouses, the comprehensive return cycle of energy saving and maintenance saving is about 1.5-2.5 years.

Q5: Does HRLUX provide free Dia lux simulation service for new projects?

A5: Yes. HRLUX provides free professional Dia lux optical simulation and customized lighting layout scheme for warehouse and factory lighting new construction and renovation projects.

 

 

 Related Products

 

  

 

Your Reliable Outdoor Lighting Partner

 

HRLUXSOLAR focuses on mid-to-high-end outdoor lighting with strict quality standards and a rigorous, responsible team. We take quality as the core and professionalism as the foundation to provide stable and durable outdoor lighting products.We specialize in professional services for municipal and commercial engineering projects, delivering customized lighting solutions for smooth project implementation. We support flexible customization, efficient delivery and full-process technical support to meet diverse project demands.Committed to being your trusted outdoor lighting partner, HRLUXSOLAR keeps improving to create better lighting value for your projects.

 

 

Need a Dialux simulation for your project? Click here for a free lighting plan.