Case study · Logistics & warehousing
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
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.
| Area | Legacy installation | Lamphouse specification |
|---|---|---|
| Warehouse, racked storage | New build, no legacy installation | LED linear high bay, 60 W |
| Freezer room | New build, no legacy installation | LED linear high bay, 60 W, rated for frozen service |
Why it worked
Carried forward
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
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