Racked storage at the Digistics distribution facility in Cornubia, lit by 60 W LED linear high bays

Case study · Logistics & warehousing

A cold store lit right at the design stage instead of retrofitted later

Client

Digistics

Location

Cornubia, Durban

Division

LED Solutions

Executive summary

Digistics built a new distribution facility at Cornubia in Durban, including a freezer room. Because the lighting was specified at design stage rather than inherited, there is no before figure to report and no retrofit to fund: the building was commissioned with an estimated annual lighting consumption of 34,044 kWh, using 60 W LED linear high bays throughout. This is what the other case studies on this site are trying to get back to.

34044

kWh a year, as designed (estimated)

Figures are estimates derived from project close-out data and standard operating assumptions. They will vary with tariff, run hours and site conditions, and are indicative of this project rather than a guarantee of results on another site.

The project

What the site needed, and what we did

A new build is the only moment when lighting is genuinely free to decide. Every other project on this site is a retrofit, which means working within an existing ceiling, an existing circuit layout and an existing set of mounting positions chosen for a different technology.

The risk on a new build is the opposite of the retrofit risk. Lighting is a small line on a warehouse construction budget and it is competitively tendered late, which is exactly the condition under which a building gets fittings chosen on unit price and inherits a twenty-year operating cost in the process.

The freezer room adds a specific requirement. Fittings in frozen space have to start and run reliably at temperature, and every watt they draw becomes heat the refrigeration plant has to remove.

The lighting was specified as part of the facility design rather than tendered as a commodity at the end, working alongside the project team and the electrical installers.

60 W LED linear high bays were used through the warehouse and the freezer room. A linear high bay suits racked storage better than a round-beam fitting because the distribution follows the aisle rather than spilling across the racking, which is what allows a lower installed load to deliver usable light where people and forklifts actually work.

The result is a building commissioned at an estimated 34,044 kWh a year of lighting consumption. There is no saving to report because there was never any waste to remove.

AreaLegacy installationLamphouse specification
Warehouse, racked storageNew build, no legacy installationLED linear high bay, 60 W
Freezer roomNew build, no legacy installationLED linear high bay, 60 W, rated for frozen service

Why it worked

What made the difference

Specified at design, not tendered at the end

Lighting is a small line on a construction budget and is usually priced late. That is how buildings inherit twenty years of operating cost.

Linear high bay for racked storage

The distribution follows the aisle rather than spilling across racking, so a lower installed load delivers usable light where the work happens.

Frozen service designed in

Fittings in the freezer room have to start and run at temperature, and their heat is load the refrigeration plant carries.

Carried forward

What we would tell the next client

Get in front of the electrical design. Specifying the lighting before tender, as happened here, lets a client avoid a cost rather than recover one later, and it is a far easier conversation than a retrofit business case.

Supporting references

  1. [1]International Energy Agency, The next wave of LED lighting · https://www.iea.org/reports/the-next-wave-of-led-lighting
  2. [2]DFFE, Grid Emission Factors Report · https://www.dffe.gov.za
  3. [3]Eskom Data Portal · https://www.eskom.co.za/dataportal/

Got a site where the
lighting isn't earning its keep?

Tell us the areas, the hours they run, the lux you need to hit and your capex envelope. We'll come back inside the week with a design, a fitting schedule and a payback model.

Related: Logistics & warehousing LED