Warehouse interior LED lighting is critical for large-scale manufacturing facilities like Alcon. With 25-foot ceilings and a multi-block warehouse operation, proper lighting directly impacts visibility, safety, productivity, and operational efficiency.
Alcon Manufacturing, a global leader in eye care innovation, relies on precise warehouse logistics to fulfill orders around the world. However, their team was facing two major challenges: low visibility and inefficient fluorescent fixtures that were costing them energy and productivity.
Why Warehouse Interior LED Lighting Matters for Large Facilities?
Interior LED lighting is not just about brightness. It is about productivity, safety, energy savings, and long-term operational efficiency.
Joshua Pitts from LED Lighting of Houston designed and executed a full replacement of Alcon’s warehouse lighting system using high-powered ExsaBay High Bay LED warehouse fixtures.
Warehouse Interior LED Lighting Results and ROI
The Numbers Behind the Upgrade
Lighting performance is measured in foot candles. A foot candle is equal to one lumen per square foot, roughly 10.764 lux. Think of it as horsepower for lighting. Industry lighting guidelines are commonly referenced through the Illuminating Engineering Society (IES).
Before installation:
- Existing light levels were only 10 to 15 foot candles
After installation:
- Light levels increased to 40 to 50 foot candles
That is a dramatic improvement in usable light.
LED Lighting of Houston installed:
- 305 interior LED high bay fixtures
- Nearly 9 million total lumens
At the same time, over 500 existing T5 fluorescent fixtures were removed.
Each T5 fixture contained:
- 4 bulbs at 53 watts each, totaling 212 watts
- An internal ballast that consumes approximately 10 percent additional power
Actual energy consumption per fixture was closer to 233 watts, not 212.
The result:
- 2 year payback period
- Over 22 percent ROI
- Major reduction in maintenance costs
How Proper Warehouse Interior LED Lighting Is Designed
Warehouse interior LED lighting is not just about installing brighter fixtures. Proper design begins with a full photometric layout that calculates light distribution, mounting height, beam angles, spacing, and uniformity ratios. In large facilities with 25-foot ceilings, poor spacing can create dark spots or overlit zones that waste energy.
Our engineering team evaluated ceiling height, rack layout, aisle width, and forklift traffic patterns before selecting the appropriate high bay LED fixtures. By optimizing beam angles and lumen output, we ensured even 40 to 50 foot candle coverage across the working plane while reducing total fixture count.
A well-designed warehouse interior LED lighting system improves visibility without overlighting the space, which keeps energy consumption under control while maximizing productivity.
Productivity and Safety Improvements
Alcon’s warehouse team immediately noticed the difference.
Higher light levels made it easier to:
- Identify products accurately
- Navigate aisles safely
- Operate forklifts and heavy equipment
Better lighting directly reduces workplace hazards, especially in environments with machinery and moving equipment.
The Psychological Impact of Better Lighting
Lighting affects more than visibility. It affects mood, alertness, and overall well-being.
Research has shown that light is one of the most influential stimuli in human perception and psychophysical well-being. Brighter, properly distributed 5000K lighting can help employees feel more alert and energized during the workday.
When employees feel better, productivity increases. When productivity increases, the company benefits.
While morale may not be the primary reason to upgrade lighting, it becomes one of the strongest long-term advantages.
Why Interior LED Lighting Makes Financial Sense
There are three major takeaways from this warehouse LED lighting upgrade:
- Increased light levels improve productivity and safety
- LED fixtures reduce energy and maintenance costs
- Better lighting improves workplace morale and operational performance
By switching from outdated fluorescent technology to high-efficiency LED high bay fixtures, Alcon transformed their facility into a brighter, safer, and more efficient environment.
Ready to Upgrade Your Warehouse Lighting?
If your warehouse is still operating under low light levels or inefficient fluorescent fixtures, now is the time to evaluate an upgrade.
Give Joshua Pitts a call at (832) 740-7983 or request a quote through our warehouse lighting installation services page to see how interior LED lighting can improve your facility’s performance, safety, and bottom line.
LED Lighting of Houston is ready to design a custom lighting plan for your warehouse.
