Lighting a factory or warehouse is a big-ticket decision that affects your energy bill,
worker safety, and productivity for years. Buy wrong and you get dark aisles, constant
maintenance, and wasted power. This step-by-step guide helps owners, plant heads, and bulk
buyers get it right.
Step 1: Assess Your Space
Start with three questions: How high are the ceilings? What tasks happen in each area
(storage vs assembly)? And how many hours a day are the lights on? These decide the fixture
type, wattage, and how fast an LED upgrade pays back.
Step 2: Match Light Levels to Tasks
| Area | Recommended Lux |
|---|---|
| General storage | 150–200 lux |
| Picking / packing | 300–500 lux |
| Assembly / precision work | 500–750 lux |
Over-lighting wastes money; under-lighting risks safety. Light each zone for its task.
Step 3: Choose the Right High Bay
For ceilings above 12 feet, you need high bays. Match wattage to ceiling height (roughly
100–150W for 12–20ft, 150–250W above that) and pick the beam angle to suit — narrower for
higher ceilings. For dusty or wash-down areas, choose IP65/IP66 fixtures like PROSAFE; for general floors, a UFO
high bay such as ULTRABAY works
well.
Step 4: Compare on Efficacy & Total Cost
India’s Bureau of Energy
Efficiency encourages high-efficacy lighting. Don’t buy on wattage or sticker price.
Compare efficacy (lm/W) — aim for
130+ — and think in total cost of ownership: energy + maintenance over the
fixture’s life. LED high bays last 50,000+ hours and can cut lighting energy by up to 70%,
usually paying back within 1.5–3 years.
Step 5: Choose a Reliable Supplier
- BIS, LM-79, LM-80 certified products (proof of real performance)
- A proper lighting design for your floor, not just a price list
- Strong warranty (5 years is a good sign) and after-sales support
- Ability to supply at scale and support installation
Buyer Checklist
- Audit ceiling heights, tasks, and run-hours
- Light each zone to the right lux
- Match high-bay wattage & beam to ceiling height
- Compare efficacy (130+ lm/W) and total cost
- Insist on certifications, warranty, and a lighting design
Frequently Asked Questions
What LED wattage replaces a 400W metal halide high bay?
Typically a 120–150W LED high bay — same brightness, less than half the energy.
How much can a factory save switching to LED?
Usually 50–70% on lighting energy, plus big maintenance savings from the long LED life.
What certifications should I demand?
BIS for compliance, plus LM-79 and LM-80 to verify brightness and lifespan claims.
Reway supplies BIS-certified industrial LED lighting — ULTRABAY, BAYLITE, ORBIT, and PROSAFE — with free lighting layouts
and pan-India support.
Get a factory lighting assessment →
