Texas Logistics Warehouse Lighting UpgradeThe major distribution center in Texas was grappling with soaring energy bills and operational inefficiencies caused by aging 400W metal halide fixtures. Lighting uniformity suffered across aisles and loading zones, and maintenance crews had to replace lamps far more often than planned, resulting in frequent downtime and avoidable labor costs.ChallengeThe facility’s legacy metal halide system consumed excessive power while delivering inconsistent illumination. Poor uniformity slowed picking and safety checks, and every cycle of lamp replacements disrupted workflows. Leadership needed a retrofit path that would slash consumption, stabilize lighting quality, and limit maintenance without compromising uptime.SolutionThe warehouse replaced 200 metal halide fixtures with NGT-HB-150W LED high bay luminaires integrated with smart controls. The LED system delivered immediate reductions in wattage, tighter beam control for more even coverage, and remote monitoring for proactive maintenance planning. Smart scheduling aligned lighting output with actual operating hours, eliminating wasted runtime during low-activity periods.Results
Energy Savings – 68%: The retrofit cut the lighting load by more than two-thirds, directly improving the facility’s operating margin.
ROI Period – 1.5 years: Lower utility bills and maintenance expenses allowed the project to pay for itself in just 18 months.
Illumination Uniformity – +40%: Enhanced visibility reduced picking errors and boosted safety compliance throughout the warehouse.
Annual Cost Savings – $52,000: A combination of energy and maintenance savings delivered a substantial recurring benefit.
Why It MattersBy targeting high-consumption fixtures with LED technology and smart controls, the distribution center transformed an aging lighting system into a strategic asset. The new setup delivers consistent brightness, minimizes disruptions, and keeps operational costs predictable—demonstrating how lighting upgrades can accelerate ROI in large-scale logistics environments.
