8 Common Mistakes to Avoid When Upgrading to LED Warehouse Lights
Upgrading toย LED lightingย is one of the smartest investments a warehouse can make. It improves energy efficiency, enhances visibility and safety, and reduces maintenance costs. But like any facility upgrade, transitioning to LED lights isnโt foolproof. Poor planning or execution can lead to wasted time, money, and underwhelming results.
To ensure a smooth and successful upgrade, here are some of the mostย common mistakes to avoid when upgrading toย LED warehouse lights:
Not Conducting a Proper Lighting Audit
Before replacing your current lighting, itโs essential to understand your warehouseโs specific lighting needs. Skipping this step can lead to under-lit or over-lit areas, uneven distribution, or even higher costs.
What to do instead:
- Measure your existing lighting levels (lux)
- Identify areas with insufficient or excessive lighting
- Map out the layout and ceiling height to determine proper fixture placement
Choosing the Wrong LED Fixtures
All LEDs are not created equal. Selecting the wrong fixture typeโsuch as one not designed for high ceilings or harsh environmentsโcan lead to poor performance and frequent failures.
What to do instead:
- Chooseย high bay LED fixturesย for ceilings over 15 feet
- Considerย IP-rated fixturesย for dusty or humid areas
- Useย motion sensors or daylight harvestingย where appropriate
Focusing Only on Initial Cost
Itโs tempting to go with the cheapest option to save money upfront. But inexpensiveย LED fixturesย often lack quality, efficiency, and durability. This can result in higher maintenance costs and shorter lifespans.
What to do instead:
- Compareย lumen output per watt (efficacy)
- Checkย warranty periodsย and manufacturer reputation
- Factor inย long-term energy and maintenance savings
Ignoring Color Temperature and CRI
Lighting thatโs too warm (yellowish) or too cool (bluish) can affect worker comfort, productivity, and even color accuracy when handling materials.
What to do instead:
- Opt forย 5000K color temperatureย for clear, daylight-like brightness
- Choose fixtures with aย CRI (Color Rendering Index) of 80 or higherย for true color visibility
Improper Fixture Placement
Placing lights in the wrong location or too far apart can lead to shadows, dark spots, or glare. This can impact safety and make tasks harder for your team.
What to do instead:
- Work with a lighting expert or use photometric analysis software
- Consider beam angles and spacing for uniform light distribution
- Donโt overlook vertical lighting for shelving and racks
Not Taking Advantage of Controls and Automation
One of the biggest advantages of LED lighting is the ability to integrate smart controls, but many warehouses skip this step.
What to do instead:
- Useย occupancy sensorsย to turn lights on/off automatically
- Installย dimming controlsย for energy savings during daylight hours
- Set upย zonesย to control lighting based on activity and traffic
Failing to Plan for Downtime or Installation
A disorganized upgrade process can disrupt warehouse operations, leading to lost productivity.
What to do instead:
- Schedule installation during off-hours or slow periods
- Communicate with your team about the installation timeline
- Work with professionals who can install quickly and safely
Not Applying for Rebates or Incentives
Many utilities and local governments offerย rebates or tax incentivesย for switching to energy-efficient lightingโbut businesses often miss out simply because they donโt know to ask.
What to do instead:
- Check with your utility provider or a rebate specialist
- Submit any required paperwork before starting the project
- Factor the rebate into your ROI calculations
An LED lighting upgrade is a major win for any warehouseโbut only if done right. By avoiding these common mistakes, youโll ensure your investment delivers maximum return in safety, efficiency, and savings.
Need help planning your upgrade? Electro-Matic Visual can conduct a free lighting audit and recommend the right LED solutions for your warehouse.