Project: Rhenus Genk – LED light lines in an open logistics hall

Logistics provider Rhenus relit its 8,000 m² open storage hall in Genk (Belgium) with 405 LED tri-proof lights, mounted in long light lines at 10 m across the full width of the hall. They replace 405 twin fluorescent fittings one for one. The light level on the floor rose from 210 to 300 lux, while the power dropped by 65%.

Project facts

Client	Rhenus, logistics and storage
Location	Genk, Belgium
Building	Open storage hall, approx. 8,000 m²
Completed	2026
Old lighting	405 × twin fluorescent fitting, 130W
New lighting	405 × LED tri-proof light 150 cm, 45W, 4000K
Mounting	10 m, mounting brackets, in parallel light lines
Control	On/off
Illuminance	210 → 300 lux
Planning	DIALux light study

The starting point

Rhenus uses the hall in Genk as an open storage and handling area: machines, parts and pallets are stored in blocks on the floor, with wide driving lanes for forklifts and trucks loading at the docks. The hall was lit by 405 twin fluorescent fittings of around 130W each, including ballast.

Too dark for the work on the floor

With 210 lux on average and many tubes burnt out, the light was too weak for checking goods, reading labels and driving safely between the blocks. Dark patches appeared wherever fittings had failed.

High consumption, high maintenance

Together the 405 fittings drew 52,650W, or more than 150,000 kWh per year at around 2,900 operating hours. Every failed tube at 10 m meant a lift in the middle of the working floor.

The solution

Parallel light lines for an open floor

In an open hall without racking, the goal is even light across the whole floor, not light aimed into aisles. The DIALux light study showed that parallel lines of LED tri-proof lights between the roof beams give a uniform 300 lux over the entire 8,000 m², with no dark zones between the lines. As with a trunking system, the lines run the full length of the hall, but each fitting is mounted directly on brackets, so no rail was needed. Every fluorescent fitting was replaced by one LED fitting at the same position. More on planning light lines in our guide to LED light lines and trunking systems.

405 LED tri-proof lights 150 cm

Each LED tri-proof light 150 cm of 45W delivers 9,000 lumen at 200 lm/W in neutral white 4000K. The wide 120° beam lets the light of neighbouring lines overlap on the floor, which keeps the light even between blocks of stored goods. The IP65 housing keeps out dust, and the fittings can be linked so one supply feeds a whole line. 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	405 × 130W twin fluorescent	405 × 45W LED tri-proof light	−85W per fitting
Connected load	52,650W	18,225W	−65%
Load per m²	6.6W/m²	2.3W/m²	−4.3W/m²
Illuminance	210 lux	300 lux	+43%
Consumption per year	152,685 kWh	52,852 kWh	−99,833 kWh
Electricity cost per year	€53,440	€18,499	−€34,941
CO2 per year	22.9 t	7.9 t	−15.0 t

How we calculated this

• Old: 405 × 130W = 52,650W × 2,900 h = 152,685 kWh per year.
• LED: 405 × 45W = 18,225W × 2,900 h = 52,852 kWh per year.
• Cost: 99,833 kWh × €0.35/kWh = €34,941 per year.
• CO2: 99,833 kWh × 0.15 kg/kWh = 15.0 t per year.

The saving comes with 43% more light on the floor. Replacing tubes at 10 m is no longer needed either.

Investment and payback

At current webshop prices, the 405 LED tri-proof lights cost €17,354. Half of the investment was covered by a relighting subsidy, leaving €8,677. With €34,941 lower electricity costs per year, that amount is earned back in about three months. Installation is not included in that figure, and no trunking rail had to be bought.

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 tri-proof lights would save in your own logistics hall.

The result

• Even light on the whole floor: 300 lux instead of 210 lux, without dark patches between the lines.
• 65% less power: 18,225W instead of 52,650W for the same 405 light points.
• Light lines without a rail: long, straight lines across the hall without the cost of a trunking system.
• No more lifts on the working floor: no burnt-out tubes at 10 m, and 5 years' warranty on the new fittings.
• Lower running costs: €34,941 less on electricity every year and 15 tonnes less CO2.

A similar project with light lines over high racking is our BME warehouse in Genk.

Frequently asked questions

How should light lines be laid out in an open hall without racking?

In an open hall, parallel lines at an even spacing work best, so that the beams of neighbouring lines overlap on the floor. That gives uniform light wherever goods are placed. In racking warehouses, the lines follow the aisles instead.

How many lux does a logistics hall need?

EN 12464-1 asks for around 100 to 150 lux in pure storage areas and around 300 lux where goods are handled, packed or dispatched. At Rhenus the whole hall now has 300 lux, so the floor can be used flexibly for storage and handling.

Can tri-proof lights at 10 m light an open hall evenly?

Yes, with enough fittings in parallel lines. Here 405 fittings of 9,000 lumen with a 120° beam give 300 lux across 8,000 m², or roughly one fitting per 20 m². The exact layout for your hall follows from a DIALux light study.

Can a large hall be relit while work continues?

Yes. Because every fitting is replaced one for one at the same position, the work can be done zone by zone, with the rest of the hall in use. Some photos of this project show old and new fittings side by side during the works.

Is there a subsidy for replacing fluorescent lighting in a logistics hall?

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 logistics hall?

Yes. Send us the floor plan with ceiling height and how the floor is used. We make a free DIALux light study, work out how many luminaires you need and send a non-binding quote at direct-import prices.

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