Your plant is burning energy it does not need.
Warehouses, distribution centers, manufacturing floors, and loading docks. High-bay LED retrofits for 480V industrial sites that cut energy 40-70%, eliminate restrike delays, and keep OSHA happy.
The pain points we keep seeing.
A single breaker trip, failed contactor, or lighting circuit issue can stop a line or slow shipping. Deferred electrical maintenance is a known driver of unscheduled downtime and shortened equipment life.
Metal halide drifts green as it ages. Inconsistent light levels, 10-minute restrike delays, and constant lamp failures reduce picking accuracy, create fatigue, and slow down QC on production lines.
29 CFR 1926.56 mandates 3-30 foot-candles depending on area. NFPA 70B now expects a formal electrical maintenance program. Aging HID fixtures fail the OSHA test long before anyone notices, and insurers are asking for proof.
Industrial sites burn power 16-24 hours a day. Glare and bad optics reduce scanning accuracy, and few contractors understand industrial environments. PMs are buried in vendor management with inconsistent work quality.
High-bay LED pays back fastest.
Industrial sites run 2-3 shifts — that is 4,000-6,000 burn hours per year per fixture. At those burn hours, 400W MH to 150W LED saves roughly $160-$200 per fixture per year in energy alone. Add maintenance reduction (no more bucket trucks at 30ft ceilings) and payback lands at the fast end of the typical range on most sites.
- 400W metal halide to 150W LED at 5,000 burn hours/year saves approximately $180 per fixture annually
- Bucket truck cost at high-bay height: $300-$700/day — LED retrofits eliminate most of it
- Improved lighting can boost warehouse worker productivity by roughly 10% and reduce errors by 20%
- 480V voltage adds roughly 40% equipment cost — we source to beat typical wholesale
Real industrialprojects we’ve delivered.
We have retrofitted Buffalo Rock bottling plants, Schneider Electric facilities, Tecumseh Products manufacturing, BR Williams distribution warehouses, Del Monte processing, L3Harris defense manufacturing, and American Apparel production sites. Industrial retrofits are where the LED math is most favorable — high burn hours, tall ceilings, and every fixture is visible on the P&L.
Free plant audit.
One walkthrough. Fixture count, wattage inventory, burn hour math, payback in your hand before you leave the floor.