Industrial lighting retrofit value includes energy, maintenance, downtime and work quality, not just old versus new nameplate wattage. Payback needs real quantities, hours, tariffs and dimming profiles.
Measure lighting at comparable positions and conditions before and after, and document controls to verify that savings do not reduce lighting quality.
Build the baseline
Audit fixture types, measured power, quantity, hours, failures, labor, spares and illuminance.
- Separate measured and nominal power
- Record hours by zone
- Include high-level service and downtime
Compare complete solutions
Evaluate LED fixtures, layout changes, circuits, sensing and dimming rather than unit price only.
- Maintain or improve lighting quality
- Check driver-control compatibility
- Pilot higher-risk zones
Calculate payback from cash flow
Annual savings include electricity, maintenance and avoided downtime with transparent price, depreciation and operation assumptions.
- State tariff assumptions
- Separate theoretical and conservative savings
- Include installation and commissioning
Accept lighting and energy
Measure illuminance, uniformity, actual power, control triggers and operating records after installation.
- Use matching pre/post points
- Verify delay and minimum output
- Review monthly energy
