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What Is Needed For Warehouse Lighting Design?
Arlen Conan
Written By: Arlen Conan Last Update: April 27, 2025

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What Is Needed For Warehouse Lighting Design?

I. Key Lighting Design Calculations (Practical Formulas)

1. Lumen Method Formula (Determining Fixture Quantity)

\[ N = \frac{E \times A}{\varphi \times U \times M} \]
    • N: Number of fixtures
    • E: Target illuminance (lux)
    • A: Area (m²)
    • ϕ: Luminous flux per fixture (lumens, e.g., 24,000 lm for a 200W LED)
    • U: Utilization factor (0.4–0.8; lower for high-bay warehouses due to light loss)
    • M: Maintenance factor (0.7 for dusty environments)

    2. Example Calculation

    For a 1,000 m² picking zone (target: 500 lux), using 200W LED fixtures (24,000 lm), U=0.6U=0.6, M=0.7M=0.7:

    N=500×100024000×0.6×0.749 fixturesN=24000×0.6×0.7500×100049 fixtures


    II. Critical Factors Affecting Lighting Requirements (Optimization Details)

    1. Ceiling Height & Fixture Placement

    • Low ceilings (<5m): Use wide-beam LEDs for uniform distribution.
    • High ceilings (>10m): Deploy high-bay fixtures with narrow optics to minimize wasted light.

    2. Reflectivity of Goods & Surfaces

    • Dark-colored goods/racks: Increase illuminance by 20–30% (dark surfaces absorb light).
    • Light-colored walls/floors (reflectivity >70%): Reduce illuminance by 10-15% (utilize reflected light).

    3. Color Temperature & Visual Comfort

    • Storage areas: 3000K–4000K (warm white, energy-efficient).
    • Work zones: 4000K–5000K (neutral white, enhances focus and reduces fatigue).

    4. Energy Efficiency & Smart Controls

    • Zoned dimming: Motion sensors adjust brightness (e.g., aisles dim to 50% when unoccupied).
    • Daylight harvesting: Automatic dimming in skylit areas to avoid over-illumination.


    III. Fixture Types & Recommendations (By Application)

    Fixture Type Efficacy (lm/W) Lifespan (hrs) Best For Key Notes
    LED High-Bay Lights 120–200 50,000+ General use, high ceilings Anti-glare optics for operator comfort
    LED Linear Strips 100–150 50,000+ Rack lighting, task areas Recessed mounting to avoid glare
    HID (High-Pressure Sodium) 80–100 20,000 Legacy warehouse retrofits Poor CRI (<30), unsuitable for picking
    Explosion-Proof Lights 80–150 30,000+ Hazardous/cold storage Must meet ATEX/Ex II certification

    Key Takeaways

    • Precision matters: Adjust calculations for ceiling height, reflectivity, and task requirements.
    • LEDs dominate: Highest efficiency and longevity for warehouses.
    • Smart controls = savings: Automated dimming can reduce energy use by 30–40%.

    For complex layouts, use DIALux or similar software to simulate light distribution and eliminate dark spots.

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