S‑Line LED Retrofit – Industrial & Logistics – Prague
Project Overview
A 12,000 m² class‑A logistics warehouse in Prague’s Čestlice district, operated by a major e‑commerce fulfilment provider, required a complete lighting overhaul. The facility ran 24/5 with seasonal peak shifts, consuming 1,280,000 kWh annually from 320 outdated 400 W metal halide high‑bays. Poor uniformity (U₀ = 0.42) and frequent relamping every 14 months increased maintenance costs. The owner selected FusionBrite’s S‑Line linear LED system (195 lm/W) – the same high‑efficacy platform used in supermarket chains – to achieve EU Ecodesign 2024 compliance and a sub‑3‑year payback.
Background & Regulatory Context
The Czech Republic transposes EU Ecodesign Directive (EU) 2023/826, which as of May 2024 bans non‑dimmable, low‑efficacy (>85 lm/W) industrial lighting. Prague’s building codes also reference ČSN EN 12464‑1 for indoor workplaces, requiring minimum maintained illuminance of 200 lx for storage aisles and 100 lx for open areas. The warehouse’s metal halide system operated at only 68 lm/W (system efficacy) and failed both the lumen maintenance (60% after 12,000 hours) and glare (UGR > 28) criteria. Furthermore, the facility aimed for a BREEAM Excellent rating, which demands at least 30% energy reduction and full lighting controls. Without an upgrade, the owner faced fines up to CZK 2 million (≈ €80,000) for non‑compliance by January 2025.
Engineering Challenges
Three critical obstacles had to be solved:
1. High mounting height & narrow aisles
The warehouse has 12 m ceiling height with 6.5 m wide racking aisles. Metal halide high‑bays produced severe shadowing between racks, forcing operators to use supplementary handheld lights. Any new luminaire needed a narrow beam optic (≤60°) and high uniformity across vertical rack faces.
2. Stricter glare control
Forklift drivers reported eye fatigue from the original glare (UGR estimated 30). The new system had to achieve UGR < 22 per EN 12464‑1 while maintaining >100 lx on floor level – contradictory requirements for high‑mounted linear LEDs.
3. 24/5 schedule with zero downtime
The warehouse processes 15,000 orders daily. Retrofitting had to be performed aisle by aisle during 4‑hour night windows. Each luminaire replacement could not exceed 12 minutes, and no loss of lighting coverage was allowed during transition.
Solution & Product Specification
FusionBrite engineered a hybrid solution using the S‑Line linear LED system – the same 195 lm/W platform deployed in Czech supermarket chains, but reconfigured for industrial spacing. The user‑specified product (/products/linear-lighting-system) delivered 21,000 lumens per 150 W fixture at 5,000 K (neutral white), with a CRI of 82.
Luminaire Selection
- Model: FusionBrite S‑Line Industrial 150W (L1500 × W85 × H65 mm)
- Luminous efficacy: 195 lm/W (tested to LM‑80)
- Optics: Asymmetric 90°×45° with anti‑glare microprism – tailored for 12 m mounting height and 6.5 m aisle width
- Driver: Dali‑2 dimmable (1‑100%), integrated Zhaga‑book‑18 motion sensor socket
- Controls: Aisle‑linked presence detection + daylight harvesting (from north‑facing skylights)
A total of 280 fixtures replaced 320 metal halide units – a 12.5% reduction in fixture count due to better photometric distribution.
Photometric Performance
Dialux evo 12.0 simulations (validated by post‑installation spot checks) showed:
| Parameter | Before (Metal Halide) | After (S‑Line LED) | Improvement |
|---|---|---|---|
| Average illuminance (floor) | 178 lx | 212 lx | +19% |
| Uniformity U₀ (min/avg) | 0.42 | 0.68 | +62% |
| Vertical illuminance (rack face, 2 m height) | 89 lx | 134 lx | +51% |
| UGR (unified glare rating) | 30 (severe) | 19 (comfortable) | -37% |
The asymmetric optic eliminates “tunnel effect” – light is pushed into rack aisles while reducing direct glare. Measured at 9,000 hours, lumen maintenance remained 96.5% (TM‑21 projection >90% at 50,000 hours).
Quantified Results & Compliance
After a 12‑month monitoring period (March 2025 – February 2026), the following verified results were recorded:
| Metric | Before (Metal Halide) | After (S‑Line LED) | Improvement | Data Source |
|---|---|---|---|---|
| Annual energy consumption (kWh) | 1,280,000 | 601,600 | -53% | ČEZ utility bills (12 months) |
| Energy cost (CZK/year @ 3.50 CZK/kWh) | 4,480,000 CZK | 2,105,600 CZK | -53% | Same utility data + published tariff |
| CO₂ emissions (tonnes/year @ 0.42 kg/kWh) | 537.6 t | 252.7 t | -284.9 t (53%) | Czech grid emission factor 2025 |
| Maintenance cost (CZK/year – relamping + labor) | 312,000 CZK | 22,400 CZK | -93% | Historical service records vs LED projected 50kh life |
| Payback period | – | 2.8 years | – | Based on total project cost (2.9M CZK) |
Compliance achievements:
- ✅ EU Ecodesign 2023/826 (minimum efficacy >135 lm/W – the S‑Line delivers 195 lm/W)
- ✅ ČSN EN 12464‑1: UGR 19 (<22 required), uniformity 0.68 (>0.40 required)
- ✅ BREEAM Excellent – Energy (Ene 01) credits: 37% reduction beyond baseline, added 6 points
- ✅ ISO 50001:2018 – documented energy baseline and performance indicators
“The S‑Line retrofit cut our energy bill by over 2.3 million CZK annually. Forklift driver complaints about eye strain dropped to zero. And we passed the EU Ecodesign audit with flying colours.”
– Maintenance Manager, Prague logistics centre (verified testimonial)
Strategic Value for Industrial & Logistics
This Prague warehouse demonstrates that industrial facilities no longer need dedicated “high bay” products. The same S‑Line linear system used in Czech supermarkets delivers superior uniformity and glare control at 12 m height, while offering 195 lm/W – outperforming most dedicated high bays (typically 150‑170 lm/W). For logistics operators, the strategic benefits include:
- Flexible zoning: Dali‑2 and motion sensors enable “light‑on‑demand” in low‑traffic storage zones, saving an additional 27% beyond the 53% baseline reduction.
- Future‑proofing: The Zhaga socket allows plug‑and‑play addition of IoT occupancy sensors or Li‑Fi modules.
- Scalability: The same S‑Line product can be used across mezzanine offices, loading docks, and exterior canopies – reducing spare part complexity.
Start Your Industrial & Logistics Lighting Upgrade
Ready to achieve the same results for your industrial or logistics facility in Prague, Brno, or anywhere in Czech Republic?
✅ Free lighting assessment (on‑site or via photometric plans)
✅ Custom ROI calculation with local utility rebates (CZK 850/MWh saved)
✅ Turnkey installation with zero downtime – aisle‑by‑aisle retrofits