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Why Lighting Controls Matter: Industrial and Warehousing

How Controls Transform Industrial Spaces.

Industrial and warehouse facilities operate under demanding conditions—long hours, vast spaces, and constant activity. Lighting isn’t just about visibility in these environments; it’s about efficiency, compliance, and creating a safe, productive workspace. With rising energy costs, sustainability commitments, and stricter regulatory frameworks, businesses are under increasing pressure to reduce consumption without compromising performance.

Lighting controls have become a critical solution to meet these challenges. They allow facility managers, lighting engineers, and warehouse operators to optimise energy usage, improve safety, and align with environmental goals. In this article, we’ll explore the unique challenges of industrial lighting, the benefits of advanced control systems, and what the future holds for smart lighting in the sector.

Challenges in the Industrial and Warehouse Sector.

Lighting industrial environments is rarely straightforward. For industrial lighting, success isn’t just about “keeping the lights on.” It’s about delivering precise, adaptable, and compliant illumination that supports both operational and business objectives.

High Ceilings and Large Volumes - Fixtures are often mounted 8–15 metres above floor level, which affects distribution and maintenance.

Mixed Lighting Needs - Aisles require uniform vertical illumination, while open areas and loading bays demand higher lux levels for safety.

Harsh Conditions - Dust, humidity, and fluctuating temperatures place additional stress on luminaires and sensors.

Operational Hours - Many facilities run 24/7, meaning lighting can account for up to 80% of energy consumption in some industrial settings.

Compliance and Safety - Regulations dictate specific lux levels for certain tasks, and emergency lighting must meet stringent standards.

Without effective lighting controls, these challenges can translate into wasted energy, poor visibility, and even workplace accidents.

Benefits of Lighting Controls for Industrial and Warehouses.

Lighting controls deliver measurable improvements across several critical areas:

Energy and Cost Reduction

  • Dimming lights in unoccupied areas or during daylight hours can cut energy consumption by 40–70%.
  • Automated scheduling avoids lights being left on unnecessarily during downtime.

Operational Efficiency

  • Remote monitoring and centralised control simplify management across large or multiple sites.
  • Reduced maintenance through predictive alerts and usage data.

Enhanced Safety and Productivity

  • Brightness adjustments for different zones improve visibility for forklift operators and staff working at height.
  • Eliminating dark spots reduces accident risk in aisles and loading docks.

Extended Luminaire Life

  • Controlled output reduces strain on LEDs, lowering replacement frequency and costs.

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Its sleek design and high-performance LED technology combine to make it an excellent choice for hotel lobbies, restaurants, bars, and conference rooms, where visual appeal is just as important as functionality. Easy to install and compatible with dimming and scene-setting controls, it creates comfortable, adaptable atmospheres. With uniform, glare-free light and energy-efficient performance, it’s perfect for enhancing guest experience while reducing costs.

Find out more and view full range.

Optimised Lighting for Racking and Aisle Applications.

Warehouses present a unique challenge when it comes to lighting. Unlike open industrial spaces, they typically feature long aisles, tall storage racks, and mixed-use zones. Achieving uniform illumination across these varying conditions requires not only the right luminaires, but also the right optics—and lighting controls to make it all work efficiently.

Incorrect optics can lead to dark spots, glare, and wasted energy, particularly in racking aisles where vertical illumination is crucial for safety and accuracy. Using the correct optic means less over-lighting and fewer fixtures—delivering cost savings without compromising compliance.

How Lighting Controls Improve Safety.

Dynamic Zoning: Lighting controls allow facility managers to adjust brightness by area. For example, increasing lux levels in active loading bays while dimming unused zones reduces energy use without compromising safety.

Occupancy Sensors: Automatic detection ensures lights activate when workers enter a space—no dark aisles or reliance on manual switches.

Emergency Lighting Integration: Modern systems include automated testing and monitoring to guarantee compliance without disrupting operations.

Adaptive Light Levels: Controls prevent under-illumination during peak operations and over-illumination that causes glare.

Supporting Well-Being & Productivity.

Worker fatigue and discomfort can directly affect productivity. Lighting plays a major role in mitigating these issues:

Circadian Lighting: In 24/7 facilities, shifting colour temperature to mimic natural daylight helps regulate sleep-wake cycles, reducing fatigue during night shifts.

Glare Control: Overly bright or poorly directed lighting can cause headaches and eye strain. Smart dimming and uniform distribution improve comfort.

Consistent Lux Levels: Sensors maintain steady illumination, preventing dips in light that can slow down detailed tasks or inspections.

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Luceco’s Emergency DALI range brings advanced emergency lighting solutions to healthcare settings. DALI (Digital Addressable Lighting Interface) allows for individual control and monitoring of lighting fixtures. In emergency scenarios, this means that lighting systems can automatically switch to backup power, ensuring safe evacuation paths. Additionally, DALI systems can self-test and report faults, reducing maintenance efforts and ensuring compliance with safety regulations.

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Integration with Building Management Systems (BMS).

Lighting controls rarely operate in isolation anymore. In modern industrial facilities, they often integrate with Building Management Systems (BMS) to deliver complete automation.

Benefits of Integration:

  • Energy Data and Reporting – Centralised dashboards for energy monitoring and ESG compliance.
  • Cross-System Efficiency – Syncing lighting with HVAC for optimised energy usage.
  • Remote Control – Adjust settings across multiple sites from one platform.

Example: A warehouse that reduces HVAC activity in unused zones can automatically dim lights in the same area for maximum efficiency.

Sustainability and Lighting Controls.

Sustainability is no longer an optional target—it's a business imperative. Many industrial operators now face pressure to achieve net-zero goals or meet ESG reporting requirements. Lighting accounts for a significant share of electricity use in warehouses and factories, making it an obvious starting point for carbon reduction.

Lighting controls support sustainability by:

  • Reducing Waste – Lights dim or switch off in unused areas.
  • Integrating Renewables – Some control systems interface with solar or energy storage for optimised use.
  • Providing Data for Reporting – Track energy savings for compliance and CSR documentation.

Combined with LED upgrades, controls can contribute to up to 80% total energy savings, significantly reducing emissions.

Compliance and Standards in Industrial Lighting.

Industrial lighting must meet several UK and European standards, which often vary based on task or environment. Common references include:

  • CIBSE Guidelines – Recommended lux levels for industrial and storage areas.
  • HSE Requirements – Health and safety lighting for accident prevention.
  • Emergency Lighting Regulations – BS 5266 compliance for escape routes and high-risk zones.

Key Points for Compliance:

  • Task areas (assembly, inspection): 300–500 lux recommended.
  • Storage aisles: 150–200 lux for safe navigation.
  • Emergency escape lighting: Minimum 1 lux along the centre line of escape routes.

Lighting controls assist by ensuring correct illuminance levels at all times and automating emergency testing.

 

Interested in Luceco Lighting Controls?

To find out more please visit; www.luceco.com/uk/lighting-controls

Learn more about how Luceco can help support and transform your space, request a callback today!

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