Case Study: How Cinoton LED High Bay Lights Improved a Warehouse’s Productivity

Lighting is the backbone of warehouse operations. From product identification and equipment handling to safety compliance, every task depends on consistent visibility. Yet, many warehouses still rely on outdated metal halide or fluorescent fixtures that consume excessive power, fade over time, and require constant maintenance.

This warehouse lighting case study demonstrates how a logistics center overcame these issues by upgrading to Cinoton LED High Bay Lights. Within weeks, the facility achieved brighter illumination, lower operating costs, and significantly safer working conditions.

As warehouse automation expands and energy costs rise, LED warehouse lighting has become an essential investment for logistics operators who prioritize both performance and sustainability.

About the Client – A High-Demand Logistics Warehouse

The featured client is a mid-sized logistics and distribution center located in the Midwest United States. The facility covers approximately 85,000 square feet and operates 24 hours a day, processing inbound and outbound freight for e-commerce and retail partners.

Prior to the lighting upgrade, the warehouse relied on 400W metal halide lamps spaced irregularly across the ceiling. These fixtures produced uneven light coverage—some zones appeared overexposed, while others were dim and shadowed.

Forklift drivers and picking staff frequently reported difficulty reading labels and locating items in darker aisles. Maintenance teams had to replace burnt-out bulbs every two months, resulting in costly downtime and safety concerns.

The management team sought a reliable industrial LED lighting solution that could:

• Meet industry standards for illumination (above 300 lux)

• Reduce long-term energy and maintenance costs

• Improve worker comfort and productivity

The Challenge – Inefficient and Unsafe Lighting Conditions

The existing lighting system caused several major operational inefficiencies:

• Uneven illumination: Poorly distributed light led to deep shadows between shelves, increasing the risk of picking errors.

• High energy consumption: Each metal halide fixture consumed 400 watts, totaling over 120 kW per day in lighting power alone.

• Maintenance disruptions: Frequent bulb replacements required scissor lifts and halted workflow for up to 30 minutes per fixture.

• Safety concerns: Inadequate brightness in loading docks raised accident risks during forklift operation.

Industry guidelines such as IES RP-7-17 recommend a minimum of 300–400 lux for general warehouse lighting and 500 lux for inspection areas. Before the retrofit, the warehouse averaged 180 lux, falling short of recommended levels.

In short, the facility needed an energy-efficient lighting upgrade that could simultaneously improve visibility, safety, and operational efficiency—without disrupting daily operations.

The Solution – Upgrading to Cinoton LED High Bay Lights

After a full site audit, the Cinoton engineering team designed a customized LED warehouse lighting solution using:

• Cinoton 150W LED Linear High Bay Lights for narrow aisles and racking zones

• Cinoton 210W UFO LED High Bay Lights for open storage areas and loading bays

Technical Highlights

The Cinoton system also incorporated smart motion sensors and 0–10V dimming controls, allowing automatic brightness adjustments based on activity levels—further improving energy savings during off-peak hours.

This tailored design ensured compliance with OSHA and NFPA 101 workplace lighting requirements while minimizing installation complexity.

“Our goal was to deliver a solution that not only improved visibility but also created long-term financial benefits,” explained the Cinoton project engineer. “Every watt saved directly impacts a company’s bottom line.”

Implementation Process – Quick and Efficient Installation

Cinoton’s installation process was strategically designed to avoid downtime. The project was completed in just 14 days through coordinated overnight shifts.

Implementation Steps:

• Assessment & Planning: Lux measurements and energy-use benchmarking.

• Fixture Replacement: Old metal halide lamps removed safely, replaced with Cinoton LED High Bay Lights using existing mounting points.

• Wiring & Testing: Plug-and-play connection reduced rewiring costs by 35%.

• Calibration: Brightness levels optimized for each work zone, and sensor timing adjusted to avoid unnecessary activation.

• Verification: Post-installation audit confirmed average brightness increased to 320 lux.

The entire retrofit was completed without interrupting warehouse operations—a key advantage for 24-hour logistics environments.

Results – Brighter, Safer, and More Productive

The upgrade delivered immediate, measurable improvements across key operational metrics:

Enhanced Visibility and Safety

The uniform illumination eliminated shadow zones entirely, enabling faster, error-free order picking. Forklift operators reported fewer near-misses, and safety audits noted a 30% decrease in minor incidents.

Energy & Maintenance Savings

The warehouse reduced lighting-related power costs by over 40%, saving approximately $14,000 per year in electricity alone. Given the 50,000-hour lifespan of Cinoton fixtures, the ROI period is estimated at less than 18 months.

Operational Productivity

Improved brightness led to higher employee satisfaction and smoother night shifts. The management team reported measurable improvements in picking accuracy and overall throughput.

Since upgrading to Cinoton’s LED system, our workflow efficiency has increased by roughly 10%,” said the facility supervisor. “The lighting quality is excellent, and our maintenance team hardly needs to intervene anymore.

Keywords: Cinoton LED High Bay Lights, Warehouse Productivity, Energy-efficient Lighting

Customer Feedback – Voices from the Field

“After switching to Cinoton LED High Bay Lights, our warehouse feels completely different. The brightness and clarity are incredible, and our team feels much safer during night shifts. We’ve already seen a noticeable drop in power usage.”
— Operations Manager, ABC Logistics

“It’s rare to find a lighting solution that hits every target—cost, efficiency, and quality. Cinoton delivered exactly what we needed and more.”
— Maintenance Lead, ABC Logistics

Proven Results with Cinoton

• 42% reduction in energy costs

• Significant improvement in worker visibility and safety

• Drastic reduction in maintenance downtime

• Compliance with industry lighting standards (IES, OSHA)

• Improved warehouse productivity and employee morale

Cinoton’s industrial LED lighting solutions continue to set the standard for performance, reliability, and cost-effectiveness in the warehouse and manufacturing sectors.