How to save thousands of euros a year in warehouses and logistics centres

Did you know that the right lighting control can cut the energy costs of a warehouse by up to 70%? In warehouses and logistics centres, where lights are often on 24/7, lighting can be one of the largest operating costs. At the same time, the quality of lighting has a direct impact on the safety, accuracy and performance of workers.

In this article we show you how smart lighting control can reduce costs, make operations more efficient and extend the life of luminaires – and we add practical advice and tips on how to start modernising the lighting in your own warehouse.

Why is lighting control important in warehouses?

In warehouses, lighting is often taken for granted – luminaires are switched on in the morning and off in the evening, whether or not a zone is actually in use. Yet this is exactly where huge potential for better efficiency and cost savings lies. Modern lighting control offers a new view of how light can work for the business.

The most common problems in warehouse spaces (all of which can be solved) are:

1. High energy costs

Many warehouses still use older types of lighting (e.g. discharge lamps, fluorescent tubes) that stay on all the time – whether or not anyone is moving around. This leads to unnecessarily high electricity consumption, especially in unused zones such as side aisles or high-bay racking areas.

2. Poor lighting conditions

Uneven lighting, glare or, on the contrary, light that is too weak has a negative impact on employees’ daily tasks. Poor lighting can lead to:

• errors in picking and packing goods,
• misreading labels or codes,
• eye strain, loss of concentration and lower productivity,
• a higher risk of accidents (e.g. forklift collisions in poorly lit zones).

3. Lack of flexibility

The warehouse environment keeps changing – sometimes intense light is needed (e.g. for checking goods), at other times a zone stays unused for a long time. Traditional lighting often does not respond to these changes – it shines the same regardless of what is happening in the space. This leads not only to wasted energy but also to less comfort for employees.

The solution? Smart lighting control

Modern lighting control systems make it possible to adapt lighting conditions to the real needs of the operation. They use different types of sensors that automatically switch the lighting on or off, or dim it, depending on the situation.

• Motion sensors (e.g. microwave or PIR) – switch the light on only when someone is moving in the area – ideal for racking aisles or less busy zones.
• Daylight sensors – adjust the light level according to the amount of natural light, preventing excessive lighting during the day.
• Time schedules – let you set different lighting modes for work shifts, breaks or weekend operation.

How does it work in practice?

Control systems can work at different levels – from simple automatic switches to connected smart systems (e.g. DALI, IoT platforms) that:

• allow central or local control of individual luminaires,
• collect data on how the lighting is used,
• allow lighting to be optimised in real time or according to preset scenarios,
• integrate with other technologies in the building management system (BMS).

Thanks to these technologies, light can respond “intelligently” to the current situation while saving energy – without compromising lighting quality.

Energy savings – how much can you really save?

One of the biggest advantages of smart lighting control is an immediate and measurable reduction in energy costs. In warehouses where lights are on often and for long periods, the savings can be substantial.

Imagine a typical warehouse with 200 uncontrolled luminaires, each rated at 100 W and on for 16 hours a day. The monthly consumption of such lighting is around 9,600 kWh (320 kWh × 30 days), which at €0.15/kWh means costs of about €1,440 per month, or roughly €17,300 a year.

After introducing smart control:

• lighting time reduced by 50–70% (depending on the type of operation),
• annual saving: €8,600 to €12,100 on electricity alone.

A simple payback (ROI) calculation

The payback on an investment in smart lighting control is often surprisingly fast. Here is another quick calculation:

• Investment in the control system (including sensors): e.g. €15,000
• Annual energy saving: approx. €12,000
• Payback (ROI): 1.25 years

Important: For larger warehouses or operations with longer shifts, the payback can be even shorter.

 What else affects the amount you save?

• The type of existing lighting (discharge lamps, fluorescent tubes, LED).
• The size and layout of the space (open vs. racked warehouse).
• How intensive the operation is (1 shift vs. 3 shifts).
• The choice and set-up of the control system.

Other benefits of lighting control – more than just savings

Energy savings are an important reason to modernise lighting, but smart control also brings many other advantages that directly affect safety, productivity and the service life of the equipment.

🔐 Greater safety

• Better visibility in aisles, racks and loading zones reduces the risk of collisions and workplace injuries.
• Eliminating glare and shadows helps operators perceive their surroundings better.
• Lights that switch on automatically with movement – no dark spots when entering a zone.

⚙️ Better working environment and performance

• High-quality, uniform lighting helps reduce eye strain and errors (e.g. when reading labels or handling goods).
• Adapting light levels to different tasks – checking goods, packing, replenishment.
• Dynamic lighting scenes according to the time of day or type of operation.

💡 Longer luminaire life

• Control shortens operating hours, saving not only energy but also the LED luminaires themselves.
• LED technology typically reaches a service life of 50,000 to 100,000 hours – running luminaires below their maximum power extends their life.
• Less frequent maintenance = fewer outages and lower service costs.

📏 Meeting standards and legislation

Smart lighting helps meet the requirements of the EN 12464-1 standard (Lighting of indoor work places), which sets minimum illuminance, uniformity and glare control for storage and logistics areas.

• Storage areas / logistics: min. 150 lux
• Handling zones, packing: 200–300 lux

The recommended UGR (Unified Glare Rating) for warehouses is UGR < 22. If the UGR is higher, employees may be dazzled, which leads to fatigue and lower efficiency.

Start saving with controlled LED lighting

Introducing smart lighting control does not have to mean a complete refurbishment of the warehouse. On the contrary – many solutions can be implemented gradually, in a targeted way and without disrupting operations.

Step 1: Find out where you are wasting money

The first step is to assess the current situation and answer the following questions:

• Where is light being used unnecessarily or inefficiently?
• Which areas are too dark, unlit or, on the contrary, too glaring?
• How often are luminaires maintained or replaced?
• How much energy does the lighting use per month/year?
• Does the lighting meet the standard?

Tip: You can easily identify problem areas with a lux meter – measure the light level in different zones of the warehouse and compare it with the recommendations, e.g. in EN 12464-1 (150–300 lux depending on the task).

Step 2: Choose a solution designed for your needs

Smart lighting control can be simple or complex. The choice depends on the size of the warehouse, your budget and your requirements.

• Simple solutions: Microwave sensors, timers – suitable for smaller warehouses.
• Advanced systems: IoT control, BMS integration, DALI systems – suitable for large or new facilities.

Step 3: Test the savings in practice

• Start with a pilot project in one operating zone of the warehouse – usually where the savings will show fastest, for example in packing, goods receiving or dispatch.
• Draw on the know-how of lighting design specialists – the right layout, choice of luminaires and parameter settings are crucial for a result that works.

📞 Not sure where to start? We will be glad to help you design a tailor-made solution.

Conclusion

Lighting control in warehouses is not just a modern trend – it is a practical tool that gives you:

• lower costs,
• greater safety,
• happier employees.

With a simple analysis and the right technology, you can achieve a significant improvement and considerable savings within just a few months.