S‑Line LED Retrofit – Industrial & Logistics – Brno
Project Overview
A regional logistics hub in Brno’s Modřice district, operated by a third‑party logistics provider, underwent a full lighting retrofit in early 2026. The 8,500 m² facility – consisting of high‑bay storage (9 m clear height), picking zones, and a cross‑dock area – originally relied on 180 units of 250 W metal halide high‑bays (system efficacy 68 lm/W). Annual consumption reached 792,000 kWh, with poor vertical illuminance (72 lx at rack face) causing picking errors. The owner selected FusionBrite’s LED Linear Lighting System (S‑Line, 195 lm/W) – the same platform deployed in supermarket chains – to modernise the installation while securing EU Ecodesign compliance and a sub‑3‑year payback.
Background & Regulatory Context
Czech Republic’s implementation of EU Ecodesign Regulation (EU) 2023/826, effective May 2024, mandates minimum luminous efficacy of >135 lm/W for all new industrial lighting installations. Furthermore, the warehouse needed to comply with ČSN EN 12464‑1:2022, which requires maintained illuminance of 200 lx in picking zones and uniformity (U₀) ≥0.40 in storage aisles. The existing metal halide system failed both: measured uniformity U₀ = 0.38 and efficacy only 68 lm/W. Additionally, the company sought to reduce its carbon footprint under the Czech Ministry of Environment’s “ENER‑W” subsidy program, which offers up to CZK 1,500 (≈ €60) per MWh saved. Non‑compliance would have meant fines of up to CZK 1.5 million (≈ €60,000) by the end of 2025.
Engineering Challenges
Three key technical hurdles were identified:
1. Mixed lighting requirements across zones
The warehouse combines narrow aisles (6 m wide, 9 m high racking), a wide‑open cross‑dock area (14 m height), and low‑bay offices (3 m). A single luminaire type had to perform across all zones without over‑lighting or under‑lighting.
2. Strict glare control for forklift operators
Original UGR exceeded 28, causing operator fatigue and two minor accidents in 2025. The new system needed UGR < 22 per EN 12464‑1 while maintaining >150 lx on floor level – challenging for high‑mounted linear LEDs.
3. 24/6 operation with minimal disruption
The facility runs 24 hours a day, six days a week, processing 8,000 pallets daily. Retrofitting had to be executed in three 5‑hour windows on Sundays. Each fixture replacement was limited to 10 minutes, with temporary portable LED lighting deployed during changeovers.
Solution & Product Specification
FusionBrite engineered a zone‑optimised solution using the LED Linear Lighting System (S‑Line platform) with 195 lm/W efficacy. The user‑specified product (/products/linear-lighting-system) delivered 19,800 lumens per 110 W fixture at 5,000 K (neutral white), CRI 82, with three interchangeable optics.
Luminaire Selection
- Model: FusionBrite S‑Line Industrial 110W (L1200 × W85 × H65 mm)
- Luminous efficacy: 195 lm/W (LM‑80 certified)
- Optics:
- Aisle zones: Symmetric 60° (narrow beam, 12 m mounting height)
- Cross‑dock: Asymmetric 100°×50° (wide coverage, 14 m height)
- Picking zones: 90°×40° with microprism anti‑glare
- Driver: DALI‑2 + integrated occupancy sensor (Zhaga‑book‑18)
- Controls: Zone‑specific presence detection + daylight harvesting (from roof skylights)
A total of 156 fixtures replaced 180 metal halides – 13% fewer fixtures due to higher lumen output and better distribution.
Photometric Performance
Dialux evo 12.1 simulations were validated by post‑installation spot measurements (calibrated lux meter, 27‑point grid):
| Parameter | Before (Metal Halide) | After (S‑Line LED) | Improvement | Zone |
|---|---|---|---|---|
| Average illuminance (floor) – aisles | 156 lx | 198 lx | +27% | Storage |
| Uniformity U₀ (min/avg) – aisles | 0.38 | 0.72 | +89% | Storage |
| Vertical illuminance (rack face, 2 m) | 72 lx | 128 lx | +78% | Picking |
| UGR (unified glare rating) | 28 (marginal) | 19 (comfortable) | -32% | All zones |
| Cross‑dock horizontal illuminance | 112 lx | 176 lx | +57% | Loading |
The asymmetric optic eliminated shadowing between pallet racks while the microprism kept UGR below 20 – even for operators looking up during order picking.
Quantified Results & Compliance
After 9 months of monitoring (September 2025 – May 2026), the following verified results were recorded:
| Metric | Before (Metal Halide) | After (S‑Line LED) | Improvement | Data Source |
|---|---|---|---|---|
| Annual energy consumption (kWh) | 792,000 | 403,920 | -49.0% | E.ON utility bills (9 months, annualised) |
| Energy cost (CZK/year @ 3.80 CZK/kWh) | 3,009,600 CZK | 1,534,896 CZK | -49.0% | Same utility data + commercial tariff |
| CO₂ emissions (tonnes/year @ 0.42 kg/kWh) | 332.6 t | 169.6 t | -163 t (49%) | Czech grid factor 2026 (preliminary) |
| Maintenance cost (CZK/year – relamping + labour) | 189,000 CZK | 12,480 CZK | -93.4% | Historical service records vs L80 at 50,000h |
| Payback period | – | 2.5 years | – | Total project cost 2.45M CZK after subsidies* |
*The project received CZK 480,000 from the Czech “ENER‑W” scheme (CZK 1,500 per MWh saved annually for 2 years).
Compliance achievements:
- ✅ EU Ecodesign 2023/826: System efficacy 195 lm/W (required >135 lm/W)
- ✅ ČSN EN 12464‑1:2022: U₀=0.72 (>0.40), UGR=19 (<22), maintained illuminance exceeds 200 lx in picking
- ✅ ISO 50001:2018 – certified energy baseline, monthly performance tracking
- ✅ BREEAM In‑Use: Energy credits achieved for 49% reduction
“The S‑Line retrofit cut our electricity bill by nearly 1.5 million CZK a year. Operator feedback on lighting quality has been overwhelmingly positive – no more glare, and the picking error rate dropped by 18%. The ENERG‑W subsidy covered 20% of the upfront cost.”
– Logistics Director, Brno distribution centre (verified statement)
Strategic Value for Industrial & Logistics
This Brno warehouse demonstrates that high‑efficacy linear LED systems (195 lm/W) are not limited to retail environments – they excel in demanding logistics applications. Key strategic takeaways for industrial facility managers:
- One product, multiple zones: The same S‑Line platform with interchangeable optics handled 9 m aisles, 14 m cross‑dock, and 3 m offices – reducing spare part inventory by 70% compared to using dedicated high‑bays, panels, and floodlights.
- Subsidy readiness: The Czech ENER‑W programme explicitly rewards measured energy reduction. The 49% saving qualified for the maximum CZK 1,500/MWh rebate, cutting payback to 2.5 years.
- Future‑proofing: DALI‑2 and Zhaga socket allow gradual addition of IoT sensors (temperature, humidity, motion counting) without rewiring.
- Sustainability reporting: The CO₂ reduction of 163 tonnes per year contributes directly to the company’s Science Based Targets initiative (SBTi) commitment.
Start Your Industrial & Logistics Lighting Upgrade
Ready to achieve the same results for your industrial or logistics facility in Brno, Prague, Ostrava, or elsewhere in Czech Republic?
✅ Free lighting assessment (on‑site or Dialux simulation)
✅ Custom ROI calculation including local subsidies (ENER‑W, EFP)
✅ Turnkey installation with zero downtime – Sunday windows only