Modernising LED Lighting: Benefits & Savings

Switching to LED lighting reduces energy consumption in commercial installations by 60–80 % depending on the technology being replaced. When maintenance costs, service life and standards compliance are factored in, payback is typically achieved in under three years. This guide shows you how to calculate savings by segment and which standards apply.

Why legacy lighting becomes a cost driver

Mercury vapour lamps (HQL), metal halide floodlights (HIT) and fluorescent tubes are still standard in many existing buildings. Their efficacy typically lies at 60–100 lm/W; modern LED high bays achieve 150–210 lm/W. For the same light output, LED requires 50–75 % less power depending on the source technology being replaced.

There are also hidden costs: starters, ballasts and lamps in conventional systems must be replaced every 8,000–15,000 hours. At mounting heights of 8–14 metres, the cherry picker hire and labour alone generate considerable additional costs – costs that are largely eliminated over the entire LED service life.

Standards-compliant requirements by application

DIN EN 12464-1 (Lighting of workplaces – Indoor workplaces) and the legally binding ASR A3.4 set minimum requirements for maintained illuminance (Em), glare limitation (UGR) and colour rendering (Ra). Falling below these values risks breaches of health and safety law and an increased risk of accidents.

The following table summarises the key benchmark values:

Application	Em (Lux)	UGR max.	Ra min.	Recommended IP rating
Warehouse / racking faces	200	25	60	IP65
Coarse assembly / packaging	300	25	80	IP54–IP65
Production hall (medium-fine work)	500	22	80	IP54–IP65
Fine assembly / quality inspection	750	19	90	IP54
Sports hall (DIN EN 12193)	300–500	22	80	IP40–IP54
Outdoor / yard (DIN EN 12464-2)	50–200	–	60–80	IP65–IP66

Detailed lux benchmarks for all areas can be found in our guide How much lux do you need?. Everything about glare limitation is explained in our article on the UGR value in practice.

Energy savings in concrete terms: what the figures mean

Abstract percentages are of little help when making an investment decision. What matters are absolute kilowatt-hours and the resulting euro amount. The following table shows typical comparison values for common replacement scenarios in the commercial sector:

Legacy technology	Old wattage	LED replacement	New wattage	Saving	LED efficacy
HQL mercury vapour lamp	400W	LED high bay	100W	75 %	150 lm/W
HIT floodlight	250W	LED high bay	70–100W	60–72 %	150–210 lm/W
Fluorescent tube T8 (2×58W)	116W	LED tri-proof light	36–40W	65–69 %	130–150 lm/W
Halogen floodlight	500W	LED floodlight	100–150W	70–80 %	130–150 lm/W
Fluorescent tube T5 (1×54W)	54W	LED tube	18–22W	59–67 %	120–140 lm/W

The difference between lumens and lumens per watt is explained in our guide Lumens vs. lumens per watt.

Payback calculator: your individual savings

Enter your current operating data – the calculator determines your annual electricity saving, CO₂ reduction and the expected payback period for your LED investment:

A detailed step-by-step guide to manual calculation can be found in our guide Calculating LED payback period.

Segment-specific recommendations

Industry and production

Production halls require Em of 300–750 lux depending on the visual task, UGR ≤ 22 and Ra ≥ 80 in accordance with DIN EN 12464-1. Linear LED high bays or linear light systems with 1-10V or DALI dimming enable demand-led control and further reduce consumption during break periods. For spray-painting and inspection areas, Ra ≥ 90 is required.

In areas with a risk of explosion (Zones 1, 2, 21, 22), only ATEX-certified luminaires are permitted. Our range of ATEX explosion-proof LED luminaires covers all protection classes.

High-bay warehouses and logistics

Mounting heights of 8–14 metres are typical in high-bay warehouses. UFO or linear high bays with a narrow beam angle (60–90°) are recommended here to achieve the required Em of 200 lux at racking face level. IP65 protection is standard, as dust exposure and occasional cleaning spray are unavoidable.

The key maintenance advantage: with a service life of 50,000 hours and 16 operating hours per day, more than 8 years pass before a lamp replacement is due. The cherry picker stays in the warehouse.

Suitable products for your high-bay warehouse:

LED high bays for warehouses and logistics – IP65, up to 210 lm/W, 5-year warranty:

Sports halls and sports facilities

DIN EN 12193 defines illuminance levels of 300–500 lux, UGR < 22 and Ra ≥ 80 for sports halls. Uniformity of illumination is also critical to avoid shadows on playing areas. For outdoor sports facilities, the requirements of DIN EN 12464-2 apply.

Our range includes specialist solutions for LED sports field lighting, football pitch lighting and padel court lighting. Our guide on light distribution on sports fields explains standards-compliant light distribution in detail.

Outdoor areas and yards

For outdoor areas, DIN EN 12464-2 specifies Em values of 50–200 lux depending on the visual task. The minimum protection rating is IP65; in areas subject to high-pressure cleaning or water jets, IP66 is recommended. LED floodlights and LED street lights meet these requirements. For areas with irregular use, LED floodlights with motion sensor are worthwhile, reducing consumption further.

Everything about IP protection ratings to IEC 60529 is explained in our guide IP protection ratings explained.

Offices and administration

At display screen workstations, UGR ≤ 19 must be maintained in accordance with DIN EN 12464-1. Louvre luminaires and LED panels with appropriate anti-glare treatment meet this requirement. Backlit panels offer a more uniform luminance distribution than edge-lit variants – details in our guide Backlit vs. edge-lit LED panel. Our range of LED panels covers all common formats.

The hidden ROI: maintenance costs and operational reliability

The electricity saving alone is only part of the calculation. Conventional lamps in industrial halls must be replaced every 8,000–15,000 hours. With 50 luminaires in a hall at a mounting height of 10 metres, each maintenance cycle generates considerable costs for cherry picker hire, labour and lamps – plus potential production downtime during maintenance.

LED luminaires with a 50,000-hour service life and 5-year warranty significantly reduce these cycles. The maintenance cost advantage can substantially complement the pure electricity saving in many operations.

There is also the matter of operational safety: mercury vapour lamps contain mercury and are subject to EU Directive 2011/65/EU (RoHS). If broken, disposal costs and safety risks arise. LED luminaires are mercury-free.

Dimming, controls and further efficiency potential

Modern LED high bays support 1-10V or DALI dimming. Combined with daylight or presence control, a further 20–40 % of residual consumption can be saved. Particularly in warehouses with irregular occupancy, the sensor technology pays for itself quickly.

For offices and administration buildings, DALI-2 systems are well suited, enabling individual workstation control and scene management. Our guide on 0-10V, 1-10V & TRIAC dimming explains the differences between interfaces.

Colour temperature influences the concentration and wellbeing of employees. For production halls, 4000 K (neutral white) is recommended; for inspection areas, 5000–6000 K. More on this in our guide LED colour temperature: 2700K to 6000K.

Large projects: planning, quantities and service

For projects with 20 or more light points, professional light planning with DIALux is recommended. Clightstore provides this free of charge – including standards-compliant lux calculations, luminaire positions and an economic viability report. This gives you planning certainty before the investment and a robust basis for authorities or insurers.

As a B2B direct importer, we deliver across the EU within 2–5 working days. For large quantities, please contact us directly.

High-performance LED high bays for large projects – DALI & 1-10V dimmable, up to 210 lm/W:

Safety notice: electrical work must be carried out by qualified electricians

The replacement of luminaires and connection to the 230V or 400V mains must only be carried out by approved qualified electricians. DIN VDE 0100, DGUV Regulation 3 and the 5 safety rules of electrical engineering apply (isolate, secure against re-energisation, verify absence of voltage, earth and short-circuit, cover adjacent live parts). Our guide Connecting an LED lamp is intended exclusively for qualified electricians.

Frequently asked questions

How much energy do I actually save by switching to LED?

This depends on the technology being replaced. When replacing HQL mercury vapour lamps (400W) with LED high bays (100W), the saving is 75 %. For fluorescent tubes T8 replaced by LED tubes, it is typically 60–70 %. Use the payback calculator above for your specific operating data.

When does the LED investment pay for itself?

For commercial installations with 10–16 operating hours per day, the payback period is frequently between 1.5 and 3 years. When maintenance costs are included, this period shortens further. Our guide Calculating LED payback period explains the methodology in detail.

Which standards apply to workplace lighting?

DIN EN 12464-1 (indoor workplaces) and ASR A3.4 are the relevant standards. ASR A3.4 is legally binding and sets minimum illuminance levels, uniformity and glare limitation. For outdoor workplaces, DIN EN 12464-2 applies; for sports facilities, DIN EN 12193.

What IP rating do I need for my hall?

For dry production halls, IP54 is often sufficient. In areas with dust exposure, splash water or cleaning systems, IP65 is standard. For high-pressure cleaning, IP66 is recommended. IP protection ratings are defined in IEC 60529; our guide IP protection ratings explained provides a comprehensive overview.

What does UGR mean and why is it important for display screen workstations?

UGR (Unified Glare Rating) is a measure of the glare effect of a luminaire. At display screen workstations, DIN EN 12464-1 requires UGR ≤ 19. Luminaires with a higher UGR value cause fatigue and loss of concentration. Our guide on the UGR value in practice explains measurement and selection.

Are LED luminaires more environmentally friendly than conventional lamps?

Yes, for several reasons: LED luminaires are mercury-free, consume significantly less electricity and have a considerably longer service life, reducing resource use and disposal requirements. Lower electricity consumption directly means fewer CO₂ emissions from power generation.

Which LED luminaires are suitable for high-bay warehouses?

UFO or linear high bays with a 60–90° beam angle, IP65 protection and at least 150 lm/W efficacy are recommended. The wattage depends on the mounting height: at 8–10 m, 100–150W is typical; from 10–14 m, 150–240W is required. Our range of LED high bays covers all power classes.

Does Clightstore offer light planning for large projects?

Yes. Clightstore provides free DIALux light planning for commercial projects – including standards-compliant lux calculations, luminaire positions and an economic viability report. Request your light planning via the contact form.