Project: Distripond – LED high bays and LED tri-proof lights

Distripond, a supplier of professional pond construction and maintenance products in Laakdal (Belgium), replaced 60 worn-out 400W mercury vapour lamps in its 1,500 m² warehouse with 35 LED high bays 100W and 25 LED tri-proof lights 120 cm. The light on the floor more than doubled, while the energy used for lighting dropped by 82%.

Project facts

Client	Distripond, pond construction and maintenance products
Location	Laakdal, Belgium
Building	Warehouse with mezzanine, approx. 1,500 m²
Completed	2019
Old lighting	60 × 400W mercury vapour
New lighting	35 × LED high bay 100W, 25 × LED tri-proof light 120 cm 36W
Mounting	6.5 m, on brackets
Control	1-10V dimmable high bays
Planning	DIALux light study
Scope	Supply and installation by our own team

The starting point

Distripond's warehouse holds pallet racking, big bags and rolls of pond liner, with forklifts moving between the racks all day. The hall was lit by 60 mercury vapour lamps of 400W each, a total of 24,000W for roughly 1,500 m², or 16W per square metre. The installation was failing on three fronts.

Too little light

Around 150 lux on the floor: too dark for comfortable order picking and safe forklift traffic. For a warehouse with picking, 200 lux is the usual minimum (see how much lux do you need).

Failing lamps

More and more lamps had burnt out, leaving dark zones between the racks. Mercury vapour lamps have been phased out in the EU since 2015, so replacement lamps were getting hard to find.

High consumption

24,000W running 2,400 hours a year adds up to 57,600 kWh: more than €18,000 a year for lighting alone at today's electricity price of €0.32/kWh.

The solution

Light study first

Before ordering, we made a DIALux light study of the hall. It showed that every old fitting could be replaced one for one, with two luminaire types matched to the ceiling height of each zone.

Open storage area: 35 LED high bays 100W

Where the hall is open and high, 35 LED high bays 100W hang on brackets at 6.5 m above the pallet racking. One 100W high bay replaces a 400W mercury vapour lamp and still puts clearly more light on the floor, thanks to 150 lm/W and a 120° beam. The high bays are 1-10V dimmable, so the light level can be tuned per zone.

Under the mezzanine: 25 LED tri-proof lights 120 cm

Under the low mezzanine ceiling, round high bays would create bright spots and glare. Here we mounted 25 LED tri-proof lights 120 cm, 36W in rows. Linear fittings spread the light evenly over the aisles, and IP65 keeps out the dust that forklift traffic raises. Read more in our guide on choosing LED tri-proof lights.

LED luminaires used in this project

Energy savings in figures

	Before	After	Difference
Luminaires	60 × 400W mercury vapour	35 × 100W high bay, 25 × 36W tri-proof	one for one
Connected load	24,000W	4,400W	−82%
Load per m²	16.0W/m²	2.9W/m²	−13.1W/m²
Consumption per year	57,600 kWh	10,560 kWh	−47,040 kWh
Electricity cost per year	€18,432	€3,379	−€15,053
CO2 per year	8.6 t	1.6 t	−7.1 t
Average illuminance	150 lux	310 lux	+107%

How we calculated this

• Before: 60 × 400W = 24,000W × 2,400 h = 57,600 kWh per year.
• After: 35 × 100W + 25 × 36W = 4,400W × 2,400 h = 10,560 kWh per year.
• Cost: 47,040 kWh × €0.32/kWh = €15,053 per year.
• CO2: 47,040 kWh × 0.15 kg/kWh = 7.1 t per year.

Ballast losses of the old mercury vapour lamps are not counted, so the real saving was even higher.

Investment and payback

At current webshop prices, the 60 LED luminaires cost €2,626. Half of the investment was covered by an energy-efficiency subsidy, leaving €1,313. With €15,053 saved per year, the luminaires paid for themselves in about one month. Installation is not included in that figure; even with installation, a relighting with savings like these typically pays for itself within the first year.

Calculate the savings for your hall

The calculator below is pre-filled with the Distripond figures. Change the values to see what a switch to LED would save in your own building.

The result

• Twice the light on a fifth of the energy: from 150 to 310 lux with 82% less power.
• No more dark zones: even light between the racks and under the mezzanine, which makes order picking and forklift driving safer.
• Instant full light: no warm-up time as with mercury vapour lamps, and no flickering.
• Lower running costs: over €15,000 less on electricity every year and 7.1 tonnes less CO2.

Frequently asked questions

Can a 100W LED high bay really replace a 400W mercury vapour lamp?

Yes. A mercury vapour lamp produces only around 50 lm/W, and part of that light is lost in the reflector. A 100W LED high bay at 150 lm/W sends its light where it is needed. At Distripond the light on the floor more than doubled, from 150 to 310 lux, while the power per fitting dropped by 75%.

Why tri-proof lights under the mezzanine instead of high bays?

The ceiling under a mezzanine is low. Round high bays at that height create bright spots and glare. Linear 120 cm tri-proof lights spread the light evenly over the aisles and are IP65 protected against dust and moisture.

How was the saving of €15,053 per year calculated?

The old installation drew 24,000W, the new one 4,400W. At 2,400 operating hours a year that is 47,040 kWh less. Multiplied by €0.32/kWh, that gives €15,053 a year. Losses of the old ballasts are not included, so the real saving is higher.

Why is mercury vapour lighting being replaced everywhere?

Mercury vapour lamps have been phased out in the EU since 2015 under the Ecodesign rules because of their low efficiency. Replacement lamps are getting scarce and expensive, while LED uses up to 80% less energy and lasts many times longer.

Can you make a free light plan for my warehouse?

Yes. Send us a floor plan or a few photos with the 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.