Project: High Demand Brands – flicker-free LED tri-proof lights in a fashion warehouse
High Demand Brands in Tessenderlo replaced 145 flickering fluorescent fittings with flicker-free LED tri-proof lights in its 4,800 m² warehouse: 300 lux, 65% less power and €11,388 saved per year.
Fashion distributor High Demand Brands in Tessenderlo (Belgium) replaced 145 flickering twin fluorescent fittings in its 4,800 m² warehouse with 145 flicker-free LED tri-proof lights at 9 m. The light level rose from 210 to 300 lux, while the power dropped by 65%.
- Relighting of a 4,800 m² warehouse for clothing and footwear, with shelving and pallet racking.
- 145 twin fluorescent fittings of 130W replaced one for one by 145 LED tri-proof lights 150 cm of 45W at 9 m.
- Flicker-free light instead of flickering tubes, from 210 to 300 lux, planned with a DIALux light study.
- 6,525W connected load instead of 18,850W: 65% less power, 34,510 kWh and €11,388 less on electricity per year.
- Luminaire investment of €6,213, half covered by subsidy: earned back in just over three months.
Project facts
| Client | High Demand Brands, fashion and footwear distribution |
| Location | Tessenderlo, Belgium |
| Building | Warehouse, approx. 4,800 m² |
| Completed | 2024 |
| Old lighting | 145 × twin fluorescent fitting, 130W including ballast |
| New lighting | 145 × LED tri-proof light 150 cm, 45W, 4000K, flicker-free |
| Mounting | 9 m, on brackets |
| Control | On/off |
| Illuminance | 210 → 300 lux |
| Planning | DIALux light study |
The starting point
High Demand Brands stores and ships fashion and footwear from a 4,800 m² warehouse in Tessenderlo. Orders are picked by hand from shelving with many small boxes, so staff read labels and sizes all day. The warehouse was lit by 145 twin fluorescent fittings of around 130W each, including ballast.
Flickering and too dark
Several fluorescent tubes had started to flicker, which is tiring for the eyes during long picking shifts and makes small print harder to read. With 210 lux on average, the aisles between the shelving were also too dark.
Too many watts
Together the 145 fittings drew 18,850W, or more than 52,000 kWh per year at 2,800 operating hours.
The solution
One for one, at the same positions
The DIALux light study showed that one LED tri-proof light at the position of each old fitting would bring the warehouse to 300 lux. The existing mounting points and wiring could be reused, which kept the work simple and quick.
145 flicker-free LED tri-proof lights
Each LED tri-proof light 150 cm of 45W gives 9,000 lumen at 200 lm/W. The flicker-free driver gives steady light, which is easier on the eyes than ageing fluorescent tubes. Neutral white 4000K with Ra>80 shows the colours of clothing, shoes and packaging naturally, and the wide 120° beam spreads the light between the shelves from 9 m. 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 | 145 × 130W twin fluorescent | 145 × 45W LED tri-proof light | −85W per fitting |
| Connected load | 18,850W | 6,525W | −65% |
| Load per m² | 3.9W/m² | 1.4W/m² | −2.5W/m² |
| Illuminance | 210 lux | 300 lux | +43% |
| Consumption per year | 52,780 kWh | 18,270 kWh | −34,510 kWh |
| Electricity cost per year | €17,417 | €6,029 | −€11,388 |
| CO2 per year | 7.9 t | 2.7 t | −5.2 t |
How we calculated this
- Old: 145 × 130W = 18,850W × 2,800 h = 52,780 kWh per year.
- LED: 145 × 45W = 6,525W × 2,800 h = 18,270 kWh per year.
- Cost: 34,510 kWh × €0.33/kWh = €11,388 per year.
- CO2: 34,510 kWh × 0.15 kg/kWh = 5.2 t per year.
Investment and payback
At current webshop prices, the 145 LED tri-proof lights cost €6,213. Half of the investment was covered by a relighting subsidy, leaving €3,107. With €11,388 lower electricity costs per year, that amount is earned back in just over three months. Installation is not included in that figure.
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.
Savings calculator
Pre-filled with this project: 145 twin fluorescent fittings of 130W replaced by 145 LED tri-proof lights of 45W.
The result
- No more flicker: steady light from flicker-free drivers, easier on the eyes during long picking shifts.
- Brighter aisles: 300 lux instead of 210 lux between the shelving.
- 65% less power: 6,525W instead of 18,850W for the same 145 light points.
- Natural colours: 4000K with Ra>80 for clothing, shoes and packaging.
- Lower running costs: €11,388 less on electricity every year and 5.2 tonnes less CO2.
Frequently asked questions
Why do fluorescent tubes start to flicker?
Fluorescent tubes and their ballasts wear out. Near the end of their life, tubes start to flicker or take longer to ignite. LED fittings with a flicker-free driver give steady light throughout their life.
Is flicker a problem in a warehouse?
Yes. Visible flicker is tiring and distracting, and even flicker you do not consciously see can cause eye strain and headaches during long shifts. In a picking warehouse, where staff read small labels and sizes all day, steady light makes the work easier.
Which colour temperature suits a fashion warehouse?
Neutral white 4000K with good colour rendering shows the real colours of clothing, shoes and packaging without the cold look of 5000K or more. That helps when staff check colours and variants while picking.
Can tri-proof lights be used at 9 m?
Yes, with enough fittings. Here 145 fittings of 9,000 lumen at 9 m give 300 lux over 4,800 m². For higher halls or open areas without shelving, LED high bays are often the more efficient choice.
Is there a subsidy for replacing fluorescent lighting?
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 building 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 ceiling height and shelving layout. We make a free DIALux light study and send a non-binding quote at direct-import prices.
Send us the floor plan and ceiling height. We prepare a free DIALux light plan and a non-binding quote at direct-import prices, 2 to 4 times below comparable branded luminaires. Delivery throughout the EU, up to 5 years' warranty.
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