Florida Logistics Hub Improves Safety and Saves $150K Annually with LED High Bay Lights

A 1 million sq ft logistics and fulfillment center in Florida simultaneously improved worker safety and achieved over $150,000 in annual energy and maintenance savings by retrofitting its entire facility with NGTlight Smart LED High Bay Lights. The project’s primary driver was the need to improve light levels to reduce picking errors and enhance safety for the facility’s 500 employees. The upgrade from dim, flickering T5 fluorescent fixtures to sensor-enabled LED high bays not only met the safety objectives but also delivered a remarkable 1.5-year payback period.

The logistics center operated 24/7 under a failing T5 fluorescent lighting system. Light levels in the pick-and-pack aisles were dangerously low, averaging below 20 foot-candles (fc), leading to an unacceptable rate of picking errors and safety concerns from staff. The conclusion of an internal safety audit was that the lighting was a root cause of operational inefficiency and a potential liability. Furthermore, the constant need to replace failed lamps and ballasts on the 4,000-fixture system was a major drain on the maintenance team. The key objectives were to increase light levels to meet IES RP-7 standards (30-50 fc), reduce picking errors, and cut operational costs.

NGTlight was chosen for its ability to provide a complete solution: high-performance LED high bays combined with a simple, effective control system. The conclusion was that a smart system was essential to maximize savings in such a large facility. The implementation involved: 1) Replacing 4,000 6-lamp T5 fixtures with 2,000 150W NGTlight LED High Bays, a 2-for-1 replacement that was possible due to the LED's higher lumen output and superior optical control. 2) Installing a network of motion and daylight harvesting sensors. The system was programmed to maintain 35 fc in active aisles, dim to 10 fc in unoccupied aisles, and harvest daylight from the facility's numerous skylights. NGTlight's North American warehouse ensured a steady supply of products for the phased, 3-month installation.

The transformation of the facility was immediate and dramatic. The core conclusion is that the investment in high-quality lighting directly translates to improved operational performance. The new system delivered bright, uniform light that virtually eliminated shadows, leading to a 15% reduction in picking errors in the first quarter after installation. Employee feedback was overwhelmingly positive, citing reduced eye strain and a greater sense of safety. The financial results were equally strong, with the combination of fixture reduction and smart controls delivering massive savings.

The key lesson from this massive project is that a 2-for-1 fixture replacement, when enabled by superior optics and higher lumen output, can significantly reduce the total project cost (both materials and labor) while still achieving the desired light levels. The conclusion for other large-scale facilities is to work with a lighting designer to create a photometric plan rather than assuming a one-for-one replacement is necessary. The logistics company is now using this facility as a best-practice model for its other sites and is working with NGTlight to develop a national account program.