Project: BME Genk – LED light lines in an 8,000 m² racking warehouse

Logistics company BME in Genk (Belgium) relit its 8,000 m² storage hall with 450 LED tri-proof lights, mounted in continuous light lines at 10 m above the pallet racking. They replace 450 twin fluorescent fittings one for one. The light level rose from 230 to 310 lux, the power dropped by 65%, and no trunking rail was needed.

Project facts

Client	BME, logistics and storage
Location	Genk, Belgium
Building	Storage hall with pallet racking, approx. 8,000 m²
Completed	2026
Old lighting	450 × twin fluorescent fitting, 130W
New lighting	450 × LED tri-proof light 150 cm, 45W, 4000K
Mounting	10 m, mounting brackets, in light lines along the aisles
Control	On/off
Illuminance	230 → 310 lux
Planning	DIALux light study

The starting point

BME stores goods on pallets in a hall of around 8,000 m², with high pallet racking, narrow picking aisles, a multi-level shelving block and reach trucks driving all day. The hall was lit by 450 twin fluorescent fittings of around 130W each, including ballast.

Too little light in the aisles

With 230 lux on average and many tubes burnt out, the aisles between the racks were too dark for reading labels and for safe driving with reach trucks. In a racking warehouse it is not only the floor that needs light, but also the rack faces up to the top levels.

High consumption at scale

450 fittings of 130W add up to 58,500W. At around 2,900 operating hours per year, that is close to 170,000 kWh of electricity for lighting alone. Replacing failed tubes at 10 m above the racks also meant a lift and an interrupted aisle every time.

The solution

Light lines over the aisles, without a trunking rail

For a racking warehouse, continuous light lines along the aisles work better than a grid of round luminaires: the light falls between the racks and onto the rack faces instead of on top of the pallets. A trunking system is the classic way to build such lines, but for 450 light points the rail is a large extra cost. The DIALux light study showed that linkable tri-proof lights, mounted with brackets in rows along the aisles, give the same light-line effect. Each fluorescent fitting was replaced by one LED fitting at the same position. More on the choice between light lines, trunking and high bays in our guide to LED light lines and trunking systems.

450 LED tri-proof lights 150 cm

Each LED tri-proof light 150 cm of 45W delivers 9,000 lumen at 200 lm/W in neutral white 4000K. Together the 450 fittings produce around 4 million lumen, enough for 310 lux across the hall at a mounting height of 10 m. The IP65 housing keeps out dust, and because the fittings can be linked, one supply feeds a whole row. See our tri-proof light guide or all tri-proof lights 150 cm.

LED luminaire used in this project

Energy savings in figures

Every fluorescent fitting was replaced by one LED tri-proof light. The table compares the old installation with the new one.

	Old	LED	Difference
Luminaires	450 × 130W twin fluorescent	450 × 45W LED tri-proof light	−85W per fitting
Connected load	58,500W	20,250W	−65%
Load per m²	7.3W/m²	2.5W/m²	−4.8W/m²
Illuminance	230 lux	310 lux	+35%
Consumption per year	169,650 kWh	58,725 kWh	−110,925 kWh
Electricity cost per year	€59,378	€20,554	−€38,824
CO2 per year	25.4 t	8.8 t	−16.6 t

How we calculated this

• Old: 450 × 130W = 58,500W × 2,900 h = 169,650 kWh per year.
• LED: 450 × 45W = 20,250W × 2,900 h = 58,725 kWh per year.
• Cost: 110,925 kWh × €0.35/kWh = €38,824 per year.
• CO2: 110,925 kWh × 0.15 kg/kWh = 16.6 t per year.

The saving comes with 35% more light in the hall. Replacing tubes at 10 m above the racks is no longer needed either.

Investment and payback

At current webshop prices, the 450 LED tri-proof lights cost €19,283. Half of the investment was covered by a relighting subsidy, leaving €9,641. With €38,824 lower electricity costs per year, that amount is earned back in about three months. Installation is not included in that figure, and no trunking rail had to be bought.

Calculate the savings for your warehouse

The calculator below is pre-filled with the figures of this project. Change the values to see what LED tri-proof lights would save in your own warehouse.

The result

• More light in the aisles: 310 lux instead of 230 lux, with light on the rack faces up to the top levels.
• 65% less power: 20,250W instead of 58,500W for the same 450 light points.
• Light lines without a rail: continuous rows of light without the cost of a trunking system.
• No more tube replacement at height: no lifts in the aisles for burnt-out tubes, and 5 years' warranty on the new fittings.
• Lower running costs: €38,824 less on electricity every year and 16.6 tonnes less CO2.

Frequently asked questions

Light lines or high bays in a racking warehouse?

In a hall with high racks and narrow aisles, light lines along the aisles usually work better: the light falls between the racks and onto the rack faces. Round high bays suit open halls better. At BME, rows of tri-proof lights at 10 m give 310 lux in the aisles.

Is a trunking system needed for light lines in a large warehouse?

Not necessarily. A trunking rail is useful when lines must be fully continuous or when fittings are moved often. For a fixed layout, linkable LED tri-proof lights mounted with brackets in rows give the same light-line effect, without buying and installing hundreds of metres of rail.

How many tri-proof lights does an 8,000 m² warehouse need?

That depends on the racking layout, the mounting height and the required lux level. Here 450 fittings of 9,000 lumen at 10 m give 310 lux, or roughly one fitting per 18 m². For your own hall we work out the exact number and layout with a free DIALux light study.

Can hundreds of LED fittings be switched on without tripping breakers?

Yes, if the circuits are planned for the inrush current of the LED drivers. With 450 fittings the number per circuit breaker matters. Our guide on inrush current and leakage explains how many drivers can go on one breaker.

Is there a subsidy for replacing fluorescent lighting in a warehouse?

That depends on the country and region. On this project half of the luminaire investment was covered by a relighting subsidy. We tell you which schemes apply to your warehouse and supply the technical data needed for the application.

Can you make a free light plan for my warehouse?

Yes. Send us the floor plan with the racking layout and ceiling height. We make a free DIALux light study, work out how many luminaires you need and send a non-binding quote at direct-import prices.