Project: Stassen Landbouwproducten – LED high bays, tri-proof lights and floodlights

Agricultural products company Stassen Landbouwproducten in Dilsen-Stokkem (Belgium) relit around 15,000 m² of warehouses, silo buildings and yard. 110 old fittings, from 400W mercury vapour lamps to 2000W floodlights, were replaced by 20 LED high bays, 85 LED tri-proof lights and 5 LED floodlights 1000W. The site now gets more light with 55% less power.

Project facts

Client	Stassen Landbouwproducten, agricultural products
Location	Dilsen-Stokkem, Belgium
Buildings	Warehouses, silo and processing buildings, outdoor yard – approx. 15,000 m²
Completed	2026
Old lighting	110 fittings: 400W mercury vapour, 120W fluorescent battens, 2000W floodlights
High bays	20 × LED high bay 200W
Tri-proof lights	85 × LED tri-proof light 150 cm, 45W
Floodlights	5 × LED floodlight 1000W
Mounting	High bays at 12 m, suspended on chains
Control	High bays and floodlights dimmable
Illuminance	Warehouses 100 lux, silo areas 300 lux, outside 100 lux
Planning	DIALux light study

The starting point

Stassen Landbouwproducten stores and processes agricultural products on a large site in Dilsen-Stokkem. The warehouses, silo buildings and yard were still lit by a mix of older technology: 400W mercury vapour lamps in the high halls, fluorescent batten fittings of around 120W in the lower storage areas, and 2000W floodlights outside.

Too dark and unreliable

The halls were too dark for safe work with trucks and loaders, and the old lamps failed regularly. In buildings with silos, conveyors and high storage, every failed lamp means a lift or a ladder at height before the light is back.

High consumption

Together the 110 fittings drew 28,200W. At around 2,800 operating hours per year, that is close to 79,000 kWh of electricity for lighting alone, while the light output of mercury vapour and old fluorescent lamps keeps dropping as they age.

The solution

Light study first

Before ordering, we made a DIALux light study per zone. Each area got its own target: 100 lux in the warehouses, 300 lux in the silo and processing areas where people work at the installation, and 100 lux on the yard. Because every old fitting could be replaced by one LED luminaire, the existing suspension points and wiring could be reused.

Silo and processing areas: 20 LED high bays 200W

The 400W mercury vapour lamps were replaced by 20 LED high bays, hung on chains at 12 m. The luminaire can be set to 120W, 160W or 200W; here it runs at 200W for the higher light level at this height. At 210 lm/W each fitting produces around 42,000 lumen, and the 90° beam brings the light down to the floor. The high bays are 0-10V dimmable and IP65, which suits the dusty environment around silos and conveyors. More on choosing wattage and beam in our LED high bay guide and the full range in high bays 200W.

Warehouses and canopies: 85 LED tri-proof lights 45W

In the lower storage halls, under the loading canopy and in the silo building, the old fluorescent battens made way for 85 LED tri-proof lights 150 cm. Each 45W fitting delivers 9,000 lumen at 200 lm/W in neutral white 4000K. The IP65 polycarbonate housing keeps out dust from grain and feed, and the fittings can be linked in a row, which kept the rewiring simple. See our tri-proof light guide or all tri-proof lights 150 cm.

Outdoor yard: 5 LED floodlights 1000W

The five 2000W floodlights on the yard were replaced by 5 LED floodlights 1000W. Each one produces 170,000 lumen at 170 lm/W with a 90° beam, enough to light the large yard and loading zones to 100 lux at half the power. The floodlights are IP66, 1-10V dimmable and have instant full light, with no warm-up time on winter mornings. These floodlights come from our sports field lighting range, which is just as suitable for large industrial yards.

LED luminaires used in this project

Energy savings in figures

Every old fitting was replaced by one LED luminaire. The table compares the old installation with the new one.

	Old	LED	Difference
Silo and processing areas	20 × 400W mercury vapour	20 × 200W LED high bay	−4,000W
Warehouses and canopies	85 × 120W fluorescent	85 × 45W LED tri-proof light	−6,375W
Outdoor yard	5 × 2000W floodlight	5 × 1000W LED floodlight	−5,000W
Connected load	28,200W	12,825W	−55%
Consumption per year	78,960 kWh	35,910 kWh	−43,050 kWh
Electricity cost per year	€28,426	€12,928	−€15,498
CO2 per year	11.8 t	5.4 t	−6.5 t

How we calculated this

• Old: 20 × 400W + 85 × 120W + 5 × 2000W = 28,200W × 2,800 h = 78,960 kWh per year.
• LED: 20 × 200W + 85 × 45W + 5 × 1000W = 12,825W × 2,800 h = 35,910 kWh per year.
• Cost: 43,050 kWh × €0.36/kWh = €15,498 per year.
• CO2: 43,050 kWh × 0.15 kg/kWh = 6.5 t per year.

Ballast losses of the old mercury vapour and fluorescent fittings are not counted, so the real difference is even larger. Lamp replacements for failed fittings also disappear.

Investment and payback

At current webshop prices, the 110 LED luminaires cost €8,058 (20 high bays, 85 tri-proof lights and 5 floodlights). Half of the investment was covered by a relighting subsidy, leaving €4,029. With €15,498 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 site

The calculator below is pre-filled with the figures of this project. Change the values to see what LED would save in your own halls, silos or yard.

The result

• Light where it is needed: 300 lux in the silo and processing areas, 100 lux in the warehouses and on the yard, as planned in the light study.
• 55% less power: 12,825W instead of 28,200W for the same 110 light points.
• No more failures: no more burnt-out mercury vapour or fluorescent lamps at height, and 5 years' warranty on the new luminaires.
• Instant full light: no warm-up time inside or on the yard, and no flickering.
• Lower running costs: €15,498 less on electricity every year and 6.5 tonnes less CO2.

Frequently asked questions

Can mercury vapour lamps be replaced by LED one for one?

Yes. At Stassen Landbouwproducten each 400W mercury vapour lamp was replaced by one LED high bay of 200W, using the existing suspension points. The light output is higher while the power is halved. Since 2015 mercury vapour lamps may no longer be placed on the EU market, so replacement lamps are becoming hard to find.

Which LED lighting suits dusty agricultural buildings?

Choose closed luminaires with at least IP65, such as the high bays and tri-proof lights used here. They keep out dust from grain, feed and fertiliser, and can be cleaned easily. For areas with an explosion risk, ATEX-certified luminaires are required.

How much does it save to replace 120W fluorescent fittings with LED tri-proof lights?

A 45W LED tri-proof light replaces a fluorescent batten of around 120W including ballast. On this project that is 75W less per fitting, or 6,375W for 85 fittings: 17,850 kWh and €6,426 per year at 2,800 operating hours and €0.36/kWh.

Can a sports field floodlight be used to light an industrial yard?

Yes. A 1000W sports field floodlight with a 90° beam is built for large areas at height, which is exactly what a wide yard with loading zones needs. Here one 1000W LED floodlight replaces a 2000W floodlight with the same or better light on the ground.

Is there a subsidy for LED relighting?

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 site and supply the technical data needed for the application.

Can you make a free light plan for my site?

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