Project: Ecolab – LED trunking system

In its 6,000 m² storage hall in Tessenderlo (Belgium), Ecolab replaced 265 fluorescent tube luminaires with 265 LED trunking luminaires of 60W, mounted in continuous lines at 10 m and controlled via DALI. The light on the floor more than doubled from 160 to 340 lux, while the power for lighting dropped by 54%.

Project facts

Client	Ecolab
Location	Tessenderlo, Belgium
Building	Storage and logistics hall, approx. 6,000 m²
Completed	2024
Old lighting	265 × fluorescent tube luminaire, 130W
New lighting	265 × LED trunking luminaire, 60W
Mounting	Continuous trunking lines at 10 m
Control	DALI
Illuminance	160 lux before, 340 lux after
Planning	DIALux light study

The starting point

Ecolab's warehouse in Tessenderlo stores goods on high pallet racking over roughly 6,000 m², with narrow aisles, an outbound zone and constant forklift and order-picking traffic. The hall was lit by 265 fluorescent tube luminaires of 130W each, a total of 34,450W.

Too dark between the racks

With around 160 lux on the floor, the aisles were too dark for fast and error-free order picking. Labels on the upper racking levels were hard to read from the floor, and every failed tube left another dark patch.

Failing tubes and high consumption

More and more tubes had failed. Since August 2023, T5 and T8 fluorescent tubes may no longer be placed on the EU market, so keeping the old installation running would only have become harder. At the same time, 34,450W running 2,900 hours a year meant almost 100,000 kWh and more than €30,000 a year for lighting alone.

The solution

Light study first

Before ordering, we made a DIALux light study of the hall. It showed that a continuous LED trunking system following the racking aisles would double the light level, with one LED luminaire for every old fitting.

LED trunking lines above every aisle

The 265 LED trunking luminaires of 60W are mounted in continuous lines at 10 m, running exactly along the aisles between the racks. A trunking system carries power and control wiring through one rail, so the luminaires simply click in along the whole line. Linear light above the aisle lights the racking faces from top to bottom, which is exactly what order pickers need to read labels on every level. More on lighting racking aisles in our warehouse lighting guide.

DALI control

All luminaires are connected to DALI, so the light can be switched and dimmed per line or zone. Aisles that are not in use do not have to burn at full power, and the system can be extended later with sensors or schedules without rewiring.

Energy savings in figures

	Before	After	Difference
Luminaires	265 × 130W fluorescent	265 × 60W LED trunking	one for one
Connected load	34,450W	15,900W	−54%
Load per m²	5.7W/m²	2.7W/m²	−3.1W/m²
Consumption per year	99,905 kWh	46,110 kWh	−53,795 kWh
Electricity cost per year	€30,971	€14,294	−€16,676
CO2 per year	15.0 t	6.9 t	−8.1 t
Average illuminance	160 lux	340 lux	+113%

How we calculated this

• Before: 265 × 130W = 34,450W × 2,900 h = 99,905 kWh per year.
• After: 265 × 60W = 15,900W × 2,900 h = 46,110 kWh per year.
• Cost: 53,795 kWh × €0.31/kWh = €16,676 per year.
• CO2: 53,795 kWh × 0.15 kg/kWh = 8.1 t per year.

The saving from DALI dimming of unused aisles is not included, so the real saving can be higher.

Investment and subsidy

Half of the investment was covered by an energy-efficiency subsidy. Because a trunking system is configured per project, the investment depends on line lengths, wattage and control. With more than €16,000 saved every year, a relighting like this typically pays for itself within the first year. Enter your own investment in the calculator below to see the payback time for your hall.

Calculate the savings for your hall

The calculator below is pre-filled with the Ecolab figures. Change the values and add your investment to see what LED would save in your own building.

The result

• More than twice the light: from 160 to 340 lux on the floor, with every racking level clearly lit.
• 54% less power: 15,900W instead of 34,450W for the same 265 light points.
• No more failed tubes: no dark patches in the aisles and no more searching for discontinued fluorescent tubes.
• Smart control: DALI makes it possible to dim or switch per line or zone.
• Lower running costs: €16,676 less on electricity every year and 8.1 tonnes less CO2.

Frequently asked questions

What is an LED trunking system?

A trunking system is a continuous rail that carries power and control wiring, with LED luminaires clicked in along its length. It forms long, unbroken light lines, which makes it ideal for warehouses with long racking aisles. Lines can be extended, and luminaires can be swapped or repositioned without new wiring.

Why trunking instead of round high bays in a racking warehouse?

Round high bays light the floor well but leave the racking faces in the dark in narrow aisles. A linear trunking line above each aisle lights the faces from top to bottom, so labels on every level can be read. At Ecolab that raised the light level from 160 to 340 lux.

Can fluorescent tubes still be bought?

Since August 2023, T5 and T8 fluorescent tubes may no longer be placed on the EU market. Remaining stock is running out, so installations with fluorescent tubes will need to be converted to LED sooner or later.

How was the saving of €16,676 per year calculated?

The old installation drew 34,450W, the new one 15,900W. At 2,900 operating hours a year that is 53,795 kWh less. Multiplied by €0.31/kWh, that gives €16,676 a year. Extra savings from DALI dimming are not included.

Can you make a free light plan for my warehouse?

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