Warehouse Lighting Retrofit Case Study: Energy and Productivity Gains

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Warehouse Lighting Retrofit Case Study: Energy and Productivity Gains

Case study of 180,000 sq ft food-grade warehouse retrofit replacing T5 fluorescents with LED high bays, achieving 80%+ energy reduction and improved safety.

Published

June 4, 2026

Read time

3 min read

Source

Port City Logistics converted an 180,000 sq ft warehouse near Savannah from area lighting to rack storage, exposing gaps in illumination and high maintenance costs from outdated T5 fluorescent fixtures. Flex Lighting Solutions and LED Lowcountry redesigned the layout, installing 203 Essentials Series 4.0 LED high bays with occupancy sensors and photocells. The upgrade tripled light levels from 5 to 15 foot-candles, eliminated 1,144 lamp replacements, and delivered $21,500 in annual energy savings plus $215,000 projected over ten years.

Key takeaways

Replaced 143 T5 fluorescent fixtures with 203 LED high bays to match new rack layout

Increased average light levels from 5 to 15 foot-candles in aisles and open areas

Achieved over 80% energy reduction and $21,500 annual savings via sensors and photocells

Eliminated recurring maintenance for 1,144 fluorescent lamps and associated safety risks

Improved operator productivity and safety in reconfigured 180,000 sq ft distribution center

Market overview

SCR methodology note

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Important consideration

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