Project: LKQ – LED tri-proof lights and LED panels for warehouse and office

At its 3,000 m² site in Maasmechelen (Belgium), automotive parts distributor LKQ replaced 56 old fluorescent fittings in the warehouse and offices with 48 LED tri-proof lights and 8 LED panels 60×60. The tri-proof lights in the warehouse work with motion sensors. The light level more than doubled, from 160 to 340 lux, while the power dropped by 66%.

Project facts

Client	LKQ, automotive parts distribution
Location	Maasmechelen, Belgium
Buildings	Warehouse with loading area and offices, approx. 3,000 m²
Completed	2022
Old lighting	56 × twin fluorescent fitting, 130W
Warehouse	48 × LED tri-proof light 150 cm, 45W, 5000K
Offices	8 × LED panel 60×60, 36W
Mounting	Tri-proof lights on brackets, panels surface-mounted on the office ceiling
Control	Motion sensors
Illuminance	160 → 340 lux
Planning	DIALux light study

The starting point

LKQ distributes car parts and workshop supplies from its site in Maasmechelen. Parts are picked from shelving racks, packed at work tables and loaded into delivery vans at the loading doors, while the office team handles orders and planning. Both the warehouse and the offices were lit by 56 twin fluorescent fittings of around 130W each, including ballast.

Too dark for picking parts

With only 160 lux, the warehouse was too dark for finding small parts and reading part numbers quickly. Several tubes were broken, which left dark spots between the racks.

Lights on all day, everywhere

The old fittings were switched on for the whole working day, also in zones where nobody was working at that moment. Together they drew 7,280W.

The solution

Warehouse: 48 LED tri-proof lights with motion sensors

In the warehouse and loading area, 48 LED tri-proof lights 150 cm of 45W are mounted on brackets under the roof. Each fitting gives 9,000 lumen at 200 lm/W in daylight white 5000K, which makes part numbers and labels easy to read. Motion sensors switch the light on only in the zones where people are picking or loading. Which sensor type suits which zone is explained in our guide on PIR or HF motion sensors. See also our tri-proof light guide or all tri-proof lights 150 cm.

Offices: 8 LED panels 60×60

In the offices, 8 LED panels 60×60 of 36W are surface-mounted on the plaster ceiling. Each panel gives around 5,000 lumen with even, backlit light, and the colour temperature can be switched, so the office light can be set warmer or cooler than the warehouse. Unsure whether you need a surface-mount, recessed or suspended panel? Read our LED panel guide or see all LED panels.

LED luminaires used in this project

Energy savings in figures

The 56 old fittings were replaced by 56 new LED luminaires. The table compares the old installation with the new one at the same 2,000 operating hours.

	Old	LED	Difference
Warehouse	48 × 130W twin fluorescent	48 × 45W LED tri-proof light	−4,080W
Offices	8 × 130W twin fluorescent	8 × 36W LED panel	−752W
Connected load	7,280W	2,448W	−66%
Load per m²	2.4W/m²	0.8W/m²	−1.6W/m²
Illuminance	160 lux	340 lux	+113%
Consumption per year	14,560 kWh	4,896 kWh	−9,664 kWh
Electricity cost per year	€4,514	€1,518	−€2,996
CO2 per year	2.2 t	0.7 t	−1.4 t

How we calculated this

• Old: 56 × 130W = 7,280W × 2,000 h = 14,560 kWh per year.
• LED: 48 × 45W + 8 × 36W = 2,448W × 2,000 h = 4,896 kWh per year.
• Cost: 9,664 kWh × €0.31/kWh = €2,996 per year.
• CO2: 9,664 kWh × 0.15 kg/kWh = 1.4 t per year.

These figures assume the same 2,000 operating hours for old and new. The motion sensors in the warehouse switch the light off in zones without activity, so the real consumption is lower still.

Investment and payback

At current webshop prices, the 48 tri-proof lights and 8 LED panels cost €2,347. Half of the investment was covered by a relighting subsidy, leaving €1,173. With €2,996 lower electricity costs per year, that amount is earned back in under five months, even without counting the sensors. Installation and sensors are not included in that figure.

Calculate the savings for your building

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

The result

• More than twice the light: 340 lux instead of 160 lux, easy to read part numbers and labels.
• 66% less power: 2,448W instead of 7,280W for the same 56 light points.
• Light only where people work: motion sensors in the warehouse cut consumption further.
• Pleasant offices: even, backlit light from LED panels above the desks.
• Lower running costs: €2,996 less on electricity every year and 1.4 tonnes less CO2, before the sensor savings.

Frequently asked questions

Can warehouse and office lighting be renewed in one project?

Yes, and it is often the most efficient route: one light study, one order and one subsidy application. At LKQ the warehouse got LED tri-proof lights and the offices LED panels, both replacing the same type of old fluorescent fittings.

How much extra do motion sensors save in a warehouse?

That depends on how often zones are empty. In a parts warehouse where staff move between racks, packing tables and the loading door, many zones are unused for long periods of the day. The sensors switch those zones off, which comes on top of the 66% saving from LED itself.

Surface-mounted or recessed LED panels for an office?

Recessed panels need a suspended grid ceiling. In offices with a plaster ceiling, like here, surface-mounted panels are the simplest solution: they are fixed directly to the ceiling and give the same even light.

5000K in the warehouse and a different colour in the office?

Daylight white 5000K helps to read small part numbers in a warehouse. In offices, many people prefer slightly warmer light. The panels used here have a switchable colour temperature, so the office light can be adjusted independently.

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 and offices?

Yes. Send us the floor plans with ceiling heights, or a few photos of the current lighting. We make a free DIALux light study, work out how many luminaires and sensors you need and send a non-binding quote at direct-import prices.