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If you’re still running metal halide, high-pressure sodium, or fluorescent lighting in your commercial facility, you’re likely spending 2-3x more on energy than necessary. LED technology has matured dramatically — offering superior light quality, longer life, and dramatically lower operating costs compared to traditional lighting sources.
This guide breaks down the real numbers so you can make an informed decision for your business.
The Cost of Traditional Lighting
Traditional commercial lighting technologies — metal halide (MH), high-pressure sodium (HPS), and T8/T12 fluorescent — have several hidden costs beyond the electricity bill:
- Higher energy consumption: A 400W metal halide fixture uses approximately 458W total (including ballast losses) to produce about 20,000 lumens initially
- Lumen depreciation: MH fixtures lose 30-40% of their light output within the first 10,000 hours, meaning they’re underperforming for most of their life
- Shorter lifespan: MH lamps last 10,000-20,000 hours vs. 100,000+ hours for LED
- Maintenance costs: Lamp replacements, ballast failures, and lift rental for high-ceiling fixtures add up quickly
- Warm-up time: MH fixtures take 5-15 minutes to reach full brightness and 15-20 minutes to restrike after a power interruption
LED Advantages: By the Numbers
Energy Savings
Here’s a typical comparison for a 50,000 sq ft warehouse with 50 fixtures:
| Metric | Metal Halide | LED | Savings |
|---|---|---|---|
| Fixture wattage | 400W (458W total) | 150W | 67% |
| Total system watts (50 fixtures) | 22,900W | 7,500W | 15,400W |
| Annual kWh (4,380 hrs/yr) | 100,302 kWh | 32,850 kWh | 67,452 kWh |
| Annual energy cost ($0.12/kWh) | $12,036 | $3,942 | $8,094/year |
| 10-year energy cost | $120,360 | $39,420 | $80,940 |
Maintenance Savings
Over a 10-year period, the maintenance savings are equally significant:
- MH lamp replacements: 50 fixtures × 5 replacements × $25/lamp = $6,250
- MH ballast replacements: 50 fixtures × 1 replacement × $80/ballast = $4,000
- Labor for replacements: Lift rental + electrician time = approximately $8,000
- LED maintenance over 10 years: $0 (100,000+ hour rated life exceeds 10 years at 12 hrs/day)
Total 10-year maintenance savings: approximately $18,250
Total Cost of Ownership
Combining energy and maintenance, a typical 50-fixture warehouse saves approximately $99,190 over 10 years by switching to LED. With utility rebates covering 30-50% of the initial investment, most projects pay for themselves in 12-24 months.
Beyond the Numbers: Quality of Light
LED doesn’t just save money — it delivers better light:
- Instant on/off: Full brightness immediately, no warm-up time
- Consistent output: LED maintains 90%+ of initial lumens throughout its life
- Better color rendering: CRI 80+ (vs. CRI 65-70 for MH) means colors look natural and products are easier to inspect
- Dimmable: 0-10V dimming to 10% output, enabling daylight harvesting and occupancy-based controls
- No flicker: LED eliminates the 60Hz flicker common with magnetic ballasts
Making the Switch
There are two main approaches to LED conversion:
- Full fixture replacement: Remove old fixtures and install new LED high bays. Best for facilities with old or damaged fixtures. Typical cost: $200-500 per fixture installed.
- Retrofit kits: Keep the existing housing and replace the lamp and ballast with an LED module. Lower cost but limited to compatible fixture types. Typical cost: $100-250 per fixture.
At Stasy’s Art 2.0, we evaluate both options for every project and recommend the most cost-effective approach. Our free lighting assessment includes energy calculations, ROI projections, and utility rebate identification.
Ready to calculate your savings? Contact us for a free energy audit and LED conversion proposal.
