Logistics Warehouse LED Lighting Retrofit – Brisbane
Project Overview
FusionBrite partnered with a leading logistics provider in Brisbane, QLD to modernize the lighting infrastructure across a 15,000 sqm distribution centre. The project replaced outdated 400W UFO high-bay fixtures with a cutting-edge ultra-high efficacy linear LED lighting system (195 lm/W). By integrating intelligent motion sensors and a “True-Dummy-True” modular design, the facility achieved a 78% reduction in energy consumption while improving illumination uniformity for safer operations.
Background
The logistics facility operates 24/7, managing high-volume freight movements for national distribution. Prior to the upgrade, the warehouse relied on a conventional lighting setup that was no longer sustainable:
- 400W Metal Halide UFO High-Bays: These fixtures suffered from low luminous efficacy (approx. 110 lm/W) and significant light depreciation over time.
- Manual Switching: Lights were controlled by bank switches, meaning entire zones were illuminated at 100% brightness regardless of occupancy or natural light availability.
- High Failure Rate: The high heat output of UFO fixtures led to frequent ballast and lamp failures, causing disruptive maintenance cycles in high-rack areas.
- Poor Vertical Illumination: The spot-beam nature of UFO lights created harsh shadows between racks, making it difficult for forklift operators to read labels at height.
Challenge
The client faced three critical operational constraints that demanded an immediate lighting retrofit:
- Escalating Energy Costs: With electricity prices rising, the warehouse’s annual lighting bill exceeded $145,000. The client required a solution that could drastically cut this OPEX.
- Occupancy Inefficiency: Large portions of the warehouse (storage aisles, bulk stack areas) remain unoccupied for long periods. Keeping these areas lit at full brightness represented a massive waste of energy.
- Maintenance Downtime: Replacing failed lamps in a 15-meter-high racking system required scissor lifts and shutdowns of adjacent aisles, disrupting logistics flow and incurring high labor costs.
Solution
FusionBrite designed and installed a smart linear LED track lighting system, specifically engineered for large-scale logistics environments to maximize both efficiency and control.
Products Installed
- FusionBrite Ultra-Efficiency Linear LED Track Lights (195 lm/W)
- Modular Design: Implemented an alternating pattern of True Light Modules (with Sensors) + Dummy Light Modules + True Light Modules.
- Benefit: This reduced the total connected wattage by 30% compared to a full grid of active lights, without compromising aisle coverage or uniformity.
- Integrated Microwave Motion Sensors
- Function: 360° radar detection capable of penetrating pallet stacks to detect subtle movements.
- Dimming Logic: Automatically dims lights to 10% when no motion is detected for 5 minutes, and switches off completely after 30 minutes of inactivity.
- Central Monitoring System
- Allowed facility managers to monitor real-time energy usage and override lighting schedules remotely via a cloud dashboard.
Technical Specifications
| Feature | Old System (UFO) | New System (Linear) | Improvement |
|---|---|---|---|
| Wattage per Unit | 400W | 220W (Avg.) | ✅ 45% less power |
| Luminous Efficacy | 110 lm/W | 195 lm/W | ✅ 77% more efficient |
| Total System Power | 40 kW | 8.8 kW | ✅ Lower demand |
| Beam Angle | 90° (Spot) | 120° (Wide) | ✅ Better spread |
| Dimming Capability | None | 0–100% | ✅ Full control |
Results
The retrofit delivered measurable improvements across energy, safety, and operational costs, validating the investment for the Brisbane facility.
| Metric | Before | After | Improvement |
|---|---|---|---|
| Energy Consumption | 100% | 22% | ✅ 78% reduction |
| Annual Electricity Cost | $145,000 | $31,900 | ✅ $113,100 saved |
| Maintenance Frequency | Every 12 months | Every 5 years | ✅ 80% fewer calls |
| Average Illuminance | 150 lux | 200 lux | ✅ Brighter & Safer |
| CO₂ Emissions Saved | 0 | 520 tons/year | ✅ Sustainability win |
“The 195 lm/W system is a game-changer. We cut our night-shift energy bill by nearly 80%. The lighting is brighter, safer, and the intelligent dimming works flawlessly with our workflow.”
— Operations Director, Brisbane Logistics Hub
Why 195 lm/W Matters for Warehouses
In logistics, every watt counts. Traditional UFO lights waste energy by generating heat. FusionBrite’s 195 lm/W Linear System ensures:
- Maximum Lumens, Minimum Watts: More light using less power.
- Reduced Cooling Load: Less heat generated means lower HVAC costs in warm climates.
- Future-Proof Investment: Aligns with global carbon reduction targets.
For logistics operators, this isn’t just a lighting upgrade—it’s a strategic cost-reduction initiative.
Start Your Warehouse Lighting Upgrade
Ready to eliminate energy waste in your warehouse or distribution centre with 195 lm/W technology?
✅ Free lighting assessment
✅ Custom ROI calculation
✅ Turnkey installation
Explore our LED Linear Lighting System for more technical specifications.