Project: I en Trans – 30 LED high bays replace 44 fluorescent fittings

In its 1,000 m² hall in Dilsen-Stokkem (Belgium), I en Trans replaced 44 flickering twin fluorescent fittings with just 30 LED high bays of 100W at 6 m. Fewer light points now give more light: the level rose from 400 to 500 lux, while the power dropped by 48%.

Project facts

Client	I en Trans
Location	Dilsen-Stokkem, Belgium
Building	Warehouse and workplace, approx. 1,000 m²
Completed	2024
Old lighting	44 × twin fluorescent fitting, 130W including ballast
New lighting	30 × LED high bay 100W, 4000K
Mounting	6 m, suspended from eye hooks
Control	On/off
Illuminance	400 → 500 lux
Planning	DIALux light study

The starting point

I en Trans uses its hall in Dilsen-Stokkem for storage and as a workplace, with vehicles, workbenches and parts spread across the floor. The hall was lit by 44 twin fluorescent fittings of around 130W each, including ballast.

Flickering tubes and too little light for detail work

Several tubes flickered, and 400 lux was not enough for the detailed work at the benches and around the vehicles. With 44 separate fittings, there were also many tubes and ballasts that could fail.

Too many watts

Together the old fittings drew 5,720W, or more than 13,700 kWh per year at 2,400 operating hours.

The solution

Fewer, stronger light points

Instead of replacing every fluorescent batten with another linear fitting, the DIALux light study showed that 30 round LED high bays at 6 m would light the open hall more evenly. Fewer light points means fewer fittings to install and maintain, while the higher output per fitting raises the light level to 500 lux.

30 LED high bays 100W

Each LED high bay 70W-100W is set to 100W and gives 21,000 lumen at 210 lm/W. The 90° beam is suited to the 6 m mounting height, the Philips driver gives steady, flicker-free light, and neutral white 4000K makes colours and details easy to judge. The IP65 housing keeps out dust from the workshop, and the fittings hang from eye hooks so they are quick to mount. More in our LED high bay guide or all high bays 100W.

LED luminaire used in this project

Energy savings in figures

The table compares the old installation with the new one.

	Old	LED	Difference
Luminaires	44 × 130W twin fluorescent	30 × 100W LED high bay	14 fewer light points
Connected load	5,720W	3,000W	−48%
Load per m²	5.7W/m²	3.0W/m²	−2.7W/m²
Illuminance	400 lux	500 lux	+25%
Consumption per year	13,728 kWh	7,200 kWh	−6,528 kWh
Electricity cost per year	€4,530	€2,376	−€2,154
CO2 per year	2.1 t	1.1 t	−1.0 t

How we calculated this

• Old: 44 × 130W = 5,720W × 2,400 h = 13,728 kWh per year.
• LED: 30 × 100W = 3,000W × 2,400 h = 7,200 kWh per year.
• Cost: 6,528 kWh × €0.33/kWh = €2,154 per year.
• CO2: 6,528 kWh × 0.15 kg/kWh = 1.0 t per year.

The saving comes with 25% more light. The high bays can also be set to 70W, which would save more where 500 lux is not needed.

Investment and payback

At current webshop prices, the 30 LED high bays cost €1,979. Half of the investment was covered by a relighting subsidy, leaving €989. With €2,154 lower electricity costs per year, that amount is earned back in under six months. Installation is not included in that figure.

Calculate the savings for your hall

The calculator below is pre-filled with the figures of this project. Change the values to see what LED high bays would save in your own hall.

The result

• More light with fewer fittings: 500 lux from 30 high bays instead of 400 lux from 44 fluorescent fittings.
• 48% less power: 3,000W instead of 5,720W.
• No more flicker: steady light from a Philips driver.
• Less maintenance: 14 fewer light points and no tubes or ballasts to replace.
• Lower running costs: €2,154 less on electricity every year and 1.0 tonne less CO2.

Frequently asked questions

Fluorescent battens: replace with tri-proof lights or high bays?

Both can work. In halls with racking or long aisles, linear tri-proof lights often fit best. In an open hall of around 6 m and more, a smaller number of round high bays often gives more even light with fewer fittings. Here 30 high bays replaced 44 fluorescent fittings.

How can fewer fittings give more light?

One LED high bay of 100W gives 21,000 lumen, more than twice a typical twin fluorescent fitting. So fewer, stronger fittings can light the same area to a higher level, as long as the spacing is planned in a light study.

Which wattage high bay suits a 6 m hall?

For around 6 m, 70W to 150W high bays with a 90° beam are a common choice, depending on the required light level and spacing. The high bay used here can be set to 70W or 100W on site.

How many lux does a workplace hall need?

For general work, assembly and repairs, around 300 to 500 lux is common, with more at detailed workplaces. At I en Trans the whole hall now gets 500 lux.

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 hall and supply the technical data needed for the application.

Can you make a free light plan for my hall?

Yes. Send us the floor plan with ceiling height, or a few photos of the current lighting. We make a free DIALux light study and send a non-binding quote at direct-import prices.

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