Warsaw Warehouse High-Bay LED Retrofit

Q: Why was a CCT of 5000K chosen for this warehouse?

A Correlated Color Temperature (CCT) of 5000K, a cool white light, was selected to maximize visual acuity and alertness for staff, which is critical for safety in a busy logistics environment. This color temperature also provides excellent contrast for the optical sensors and cameras used by the facility's automated guided vehicles, ensuring reliable navigation. The CRI was specified at 85+ for accurate color identification of labels and packages.

Q: What is the benefit of DALI-2 control in a logistics application?

DALI-2 provides addressable, digital control over every single luminaire. This allows for precise zoning, scheduling, and sensor integration, like the motion and daylight sensors used here. It enables the facility manager to monitor energy consumption and fixture status remotely, facilitating predictive maintenance. The system achieved a projected 15-20% additional energy savings on top of the LED efficiency gains.

Q: How does a UGR<22 rating benefit warehouse operations?

The Unified Glare Rating (UGR) is a measure of visual discomfort. A rating below 22 is recommended for industrial workplaces to reduce eye strain and improve safety. In a warehouse with high-mast forklifts and staff constantly looking up at racks, controlling glare is crucial. Our custom optics direct light downwards effectively, minimizing stray light that causes glare and enhancing overall comfort and concentration.

Q: What is the expected lifespan of these custom high-bay LEDs?

The luminaires are engineered for a long operational life, specified as L80B10 at over 80,000 hours. This means that after 80,000 hours of operation, 90% of the installed LEDs will still maintain at least 80% of their initial lumen output. This drastically reduces maintenance cycles and costs compared to HPS lamps, which require replacement every 20,000-24,000 hours.

Introduction — the On-site Problem

com), a Custom Indoor LED Lighting Manufacturer based in China, we were approached to develop a bespoke lighting solution for a large-scale logistics and distribution hub in Warsaw, Poland. The existing facility, scheduled for a major upgrade in 2026, was struggling with legacy high-pressure sodium (HPS) lighting.

The primary challenges included poor color rendering (CRI < 30), high energy consumption, significant light depreciation, and uneven illumination, which posed risks for both human workers and the planned integration of Automated Guided Vehicles (AGVs). The client required a solution that delivered high uniformity, excellent visual clarity, and intelligent control to minimize operational costs and enhance safety across high-rack aisles and open sorting areas.

What "custom" Meant on This Project — Capability Matrix

Our engineering process began with defining the precise technical specifications required to meet the client's operational demands. This involved customizing our existing high-bay luminaire platforms to create a solution optimized for modern logistics. The key parameters were established in close collaboration with the client's facility management and automation integration teams.

Parameter	Specification	Standard	Notes
Luminaire	XHLWX-HB21 Custom Linear High Bay	N/A	Tailored length and mounting for existing infrastructure.
Optics	CCT: 5000K / CRI: >85 / UGR: <22	EN 12464-1:2021	Optimized for visual acuity and camera/sensor performance on AGVs. Custom 30°x70° lenses for aisles.
Control System	Tridonic DALI-2 with Motion & Daylight Sensors	IEC 62386	Granular control, scene setting, and energy monitoring. Casambi Bluetooth Mesh was offered as an alternative.
Housing	IP65 Rated Aluminum Alloy, 1200mm length	IEC 60529	Protection against dust ingress and low-pressure water jets. Anodized finish for superior thermal management.
LED Chip/Driver	Osram LED Chips / Tridonic DALI-2 Driver	LM-80 / TM-21	Selected for high efficacy (>160 lm/W), long lifetime (L80B10 > 80,000 hrs), and system reliability.
Certification	CE, RoHS, ENEC (pending), ISO9001:2015	EU Directives	Ensures full compliance for the European market and adherence to quality management systems.

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Engineering Solutions

Addressing the complex needs of a hybrid human-robot workforce in a high-ceiling environment required specific engineering interventions. Our solutions focused on light quality, system intelligence, and physical durability.

How Did We Ensure Uniform Light for Both Human Staff and Automated Systems?

was critical. We used a combination of wide-beam (90°) luminaires for open floor areas and custom-developed 30°x70° asymmetrical lenses for the high-rack aisles.

This focused light vertically onto the racking faces and the floor path, minimizing wasted light and improving visibility for both picker staff and AGV navigation sensors. The entire layout was modeled in DIALux software, using our product-specific IES and LDT photometric files to simulate illuminance levels and uniformity before a single luminaire was manufactured.

What Was the Strategy for Maximizing Energy Savings Beyond Just LED Efficiency?

The transition from HPS to LED was projected to yield an immediate 50-60% energy reduction. However, we integrated a DALI-2 control system to unlock further savings.

The warehouse was zoned based on activity levels. Motion sensors were specified for low-traffic aisles, dimming lights to 10% output when vacant.

, 200 lux) by utilizing available natural light. These strategies were projected to push total energy savings to over 65%.

How Were the Luminaires Customized for Rapid Installation and Long-term Reliability?

To minimize disruption during the retrofit, the luminaires were designed with pre-installed Wieland or similar quick-connect plugs, simplifying the electrical installation process. The housing, a robust IP65-rated extruded aluminum profile, not only protects the internal components from dust common in logistics environments but also acts as a highly effective passive heat sink. This superior thermal management ensures the Osram LED chips operate at optimal temperatures, securing the projected L80B10 lifespan of over 80,000 hours and reducing long-term maintenance needs.

Project Results — Measured When Supplied; Otherwise Design Targets

As this project is planned for 2026, the following figures represent the design targets and simulation-based projections validated in DIALux. Final on-site measurements will be conducted post-commissioning.

Target Average Illuminance: 200 lux in racking aisles, 300 lux in sorting and staging areas.
Target Uniformity (U0): > 0.6 across all primary work zones.
Projected Energy Savings: >65% compared to the previous HPS system.
Projected Payback Period: < 2.5 years based on projected energy and maintenance savings.
Light Quality: CRI > 85 and UGR < 22, creating a safer and more visually comfortable environment.

Photometric Files & Compliance (IES / LDT / DIALux / CE / RoHS)

Full technical documentation was provided to the client for independent verification and planning. This included complete IES and LDT photometric files for every custom luminaire variant, enabling accurate simulation in DIALux Evo. All supplied components, from the Tridonic drivers to the completed fixtures, are certified compliant with CE (Conformité Européenne) and RoHS (Restriction of Hazardous Substances) directives, ensuring legal market access and environmental responsibility for the EU.

Frequently Asked Questions

Q: Why Was a CCT of 5000K Chosen for This Warehouse?

A Correlated Color Temperature (CCT) of 5000K, a cool white light, was selected to maximize visual acuity and alertness for staff, which is critical for safety in a busy logistics environment. This color temperature also provides excellent contrast for the optical sensors and cameras used by the facility's automated guided vehicles, ensuring reliable navigation. The CRI was specified at 85+ for accurate color identification of labels and packages.

Q: What Is the Benefit of DALI-2 Control in a Logistics Application?

DALI-2 provides addressable, digital control over every single luminaire. This allows for precise zoning, scheduling, and sensor integration, like the motion and daylight sensors used here. It enables the facility manager to monitor energy consumption and fixture status remotely, facilitating predictive maintenance. The system achieved a projected 15-20% additional energy savings on top of the LED efficiency gains.

Q: How Does a UGR<22 Rating Benefit Warehouse Operations?

The Unified Glare Rating (UGR) is a measure of visual discomfort. A rating below 22 is recommended for industrial workplaces to reduce eye strain and improve safety. In a warehouse with high-mast forklifts and staff constantly looking up at racks, controlling glare is crucial. Our custom optics direct light downwards effectively, minimizing stray light that causes glare and enhancing overall comfort and concentration.

Q: What Is the Expected Lifespan of These Custom High-bay LEDs?

The luminaires are engineered for a long operational life, specified as L80B10 at over 80,000 hours. This means that after 80,000 hours of operation, 90% of the installed LEDs will still maintain at least 80% of their initial lumen output. This drastically reduces maintenance cycles and costs compared to HPS lamps, which require replacement every 20,000-24,000 hours.

Sources and Technical References

EN 12464-1:2021: Light and lighting - Lighting of work places - Part 1: Indoor work places.
IEC 62386: Digital Addressable Lighting Interface - Part 101: General requirements - System components, and Part 102: General requirements - Control gear.
IES LM-80-21: Approved Method: Measuring Luminous Flux and Color Maintenance of LED Packages, Arrays and Modules.
CIBSE Lighting Guide 7 (LG7): Office Lighting (2015) (Referenced for principles of UGR and visual comfort applicable to work zones).

Request a Custom Quote

This project demonstrates our capability to engineer highly specific lighting systems for complex industrial environments. By combining efficient optics, intelligent controls, and robust hardware, we deliver solutions that enhance safety, reduce operating costs, and support automation.

com), a Custom Indoor LED Lighting Manufacturer based in China, our team is ready to analyze your project's unique requirements and develop a tailored lighting solution. Contact us to start a conversation and request a detailed proposal.