Solution

Warehouse Lighting Design Guide

Aisle layout, uniformity and controls.

1. Why it matters

Warehouse lighting has to deliver safe, even light down tall aisles and across open floor at the lowest possible running cost, because a warehouse runs long hours over a large area — lighting is a major, controllable slice of the operating budget. The design problem is specific: high mounting, narrow racking aisles that block light, and a strong payback case for high-efficacy fixtures plus motion controls.

Use high-efficacy high bays (or aisle-optic linears over racking), design to 150-300 lux by task, and cut the bill with motion + daylight controls.

2. Illuminance and uniformity targets

Area	Maintained lux	Notes
Bulk storage / low activity	100-150 lx
Racking aisles (picking)	150-200 lx vertical too
Packing / dispatch / value-add	300-500 lx
Loading docks	200-300 lx + exterior

3. Fixtures, optics and mounting

The fixture and its optic matter more than raw lumens, because racking blocks light. Over open floor, round UFO high bays with a wide beam give even coverage; over racked aisles, linear high bays or continuous rows with a narrow "aisle" distribution put light down into the aisle instead of onto the top of the racks. Match beam angle to mounting height.

High mounting (8-12 m): narrower beam (60-90°) to reach the floor.
Aisle running over racks: linear/continuous row with aisle optics.
IP65 where dust/wash-down; IK-rated where forklift strikes are possible.
Verify vertical illuminance in aisles, not just horizontal floor lux.

4. Controls: where warehouses save the most

Because warehouses are large and often partly idle, controls deliver the biggest energy saving — frequently 40-60% on the lighting bill. Zone the space and add occupancy sensors so seldom-visited aisles dim to a low standby level and boost to full only when someone enters; add daylight harvesting near skylights and roller doors to dim fixtures when natural light is sufficient. High-bay LEDs also switch instantly and are unharmed by frequent cycling, unlike the metal-halide they replace, which is precisely what makes motion control practical here.

5. Checklist

Set lux by task zone (bulk vs picking vs packing)
Choose beam/optic for mounting height and racking layout
Check vertical illuminance in aisles
Zone with occupancy sensors for standby dimming
Add daylight harvesting near skylights and doors

6. FAQ

High bay or linear — which for my warehouse?

It depends on the floor. Round UFO high bays suit open floor and cross-docking; linear high bays or continuous rows with aisle optics suit narrow racked aisles because they push light down into the aisle rather than onto rack tops. Many warehouses use both — high bays over open areas, linears over racking.

Will motion sensors annoy forklift drivers with delays?

Not if tuned correctly. Set a low standby level (10-20%) rather than full off so aisles are never dark, use a short boost-to-full trigger and a sensible hold time (e.g. 5-15 min), and place sensors to detect entry early. Instant-on LED means the boost is imperceptible; the result is safety plus a large saving.

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