Lighting a factory or warehouse is expensive. Large spaces, high ceilings and long operating hours mean lighting can be one of the biggest items on an industrial energy bill. Upgrading old high bay fittings to LED is one of the most dependable ways to cut that cost, and the improvement in light quality is often just as valuable.
A Real Result: BM Packaging
At BM Packaging Ltd in Huddersfield, we installed new LED high bay lighting across a cardboard factory. The results:
- 55% reduction in energy costs
- 40% increase in lux levels across the factory floor
- No factory downtime, because the installation took place out of hours, with MEWPs for safe access at height
Brighter light and lower bills at the same time is exactly what a good LED upgrade should deliver.
Why Older Lighting Costs So Much
Many industrial buildings still rely on metal halide, sodium or fluorescent high bays. These lamps use far more energy than LED for the same light output, lose brightness as they age and can take several minutes to warm up after being switched on. That warm up time means lights are often left on all day, even in areas nobody is using.
Since 2023, most T5 and T8 fluorescent tubes can no longer be sold in Great Britain, so replacement tubes are getting harder to find. If your site still depends on them, planning an upgrade now avoids a rushed replacement later.
What to Consider Before Upgrading
- Lighting design: the right fittings, spacing and mounting heights for your racking, workstations and walkways. A proper design avoids dark spots and glare.
- Controls: presence and daylight sensors can switch off or dim lights in empty aisles and near rooflights, saving even more energy. At Saint Flooring Group we installed high bay LEDs with microwave sensors.
- Environment: dusty, damp or hot areas need fittings with suitable IP and temperature ratings.
- Access: working at height needs MEWPs and careful planning around production, which is why we often work evenings and weekends.
- Emergency lighting: an upgrade is the ideal time to check that your emergency lighting still covers every escape route.
The Return on Investment
Because industrial lighting runs for long hours, LED upgrades often pay for themselves within a few years through lower energy bills. LED fittings also last far longer than traditional lamps, which cuts the cost of maintenance at height. Capital allowances may help with the cost too, so it is worth speaking to your accountant.
Why Choose Econ Electrical?
We design and install LED lighting for factories, warehouses, workshops and commercial buildings across Yorkshire and the UK. Every installation is tested and certified by our NICEIC approved team, and we plan the work around your operation to keep disruption to a minimum.
Frequently Asked Questions
How much can LED lighting save?
It depends on your existing lighting and how long it runs. At BM Packaging, our high bay LED upgrade delivered a 55% reduction in energy costs.
Can new LED fittings use the existing lighting circuits?
In many cases, yes. At BM Packaging we installed the new LED lighting on the existing circuits, which kept cost and disruption down. We check the condition of existing circuits as part of our survey.
Thinking about upgrading your lighting? Contact Econ Electrical to arrange a lighting survey and an estimate of your potential savings.
