The Starting Point
The client operated 312 metal halide high bays at 400 W each, running 20 hours a day across a facility held at −22 °C. Annual lighting consumption sat at roughly 911,000 kWh. Failure rates were high — cold starts in sub-zero conditions shorten metal halide lamp life dramatically, and every replacement required a scissor lift and a production pause.
What We Specified
140 W low-temperature-rated LED high bays with integrated motion sensors, rated for continuous operation down to −40 °C. Fixture count dropped from 312 to 268 thanks to better optical control.
The Results After 12 Months
- Energy consumption: down 68% to 291,000 kWh annually
- Motion sensor contribution: an additional 22% saving in low-traffic aisles
- Maintenance events: zero fixture failures in the first year
- Payback period: 2.3 years including the utility rebate
The Detail That Mattered Most
Standard LED drivers derate badly in freezing conditions. The specification hinged on sourcing drivers with a genuine −40 °C cold-start rating rather than a −20 °C operating rating — a distinction several competing quotes glossed over entirely.
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