Upgrading to LED lighting is one of the smartest investments a warehouse can make. It improves energy efficiency, enhances visibility and safety, and reduces maintenance costs. But like any facility upgrade, transitioning to LED lights isn’t foolproof. Poor planning or execution can lead to wasted time, money, and underwhelming results.

To ensure a smooth and successful upgrade, here are some of the most common mistakes to avoid when upgrading to LED warehouse lights:

Not Conducting a Proper Lighting Audit

Before replacing your current lighting, it’s essential to understand your warehouse’s specific lighting needs. Skipping this step can lead to under-lit or over-lit areas, uneven distribution, or even higher costs.

What to do instead:

• Measure your existing lighting levels (lux)
• Identify areas with insufficient or excessive lighting
• Map out the layout and ceiling height to determine proper fixture placement

Choosing the Wrong LED Fixtures

All LEDs are not created equal. Selecting the wrong fixture type—such as one not designed for high ceilings or harsh environments—can lead to poor performance and frequent failures.

What to do instead:

• Choose high bay LED fixtures for ceilings over 15 feet
• Consider IP-rated fixtures for dusty or humid areas
• Use motion sensors or daylight harvesting where appropriate

Focusing Only on Initial Cost

It’s tempting to go with the cheapest option to save money upfront. But inexpensive LED fixtures often lack quality, efficiency, and durability. This can result in higher maintenance costs and shorter lifespans.

What to do instead:

• Compare lumen output per watt (efficacy)
• Check warranty periods and manufacturer reputation
• Factor in long-term energy and maintenance savings

Ignoring Color Temperature and CRI

Lighting that’s too warm (yellowish) or too cool (bluish) can affect worker comfort, productivity, and even color accuracy when handling materials.

What to do instead:

• Opt for 5000K color temperature for clear, daylight-like brightness
• Choose fixtures with a CRI (Color Rendering Index) of 80 or higher for true color visibility

Improper Fixture Placement

Placing lights in the wrong location or too far apart can lead to shadows, dark spots, or glare. This can impact safety and make tasks harder for your team.

What to do instead:

• Work with a lighting expert or use photometric analysis software
• Consider beam angles and spacing for uniform light distribution
• Don’t overlook vertical lighting for shelving and racks

Not Taking Advantage of Controls and Automation

One of the biggest advantages of LED lighting is the ability to integrate smart controls, but many warehouses skip this step.

What to do instead:

• Use occupancy sensors to turn lights on/off automatically
• Install dimming controls for energy savings during daylight hours
• Set up zones to control lighting based on activity and traffic

Failing to Plan for Downtime or Installation

A disorganized upgrade process can disrupt warehouse operations, leading to lost productivity.

What to do instead:

• Schedule installation during off-hours or slow periods
• Communicate with your team about the installation timeline
• Work with professionals who can install quickly and safely

Not Applying for Rebates or Incentives

Many utilities and local governments offer rebates or tax incentives for switching to energy-efficient lighting—but businesses often miss out simply because they don’t know to ask.

What to do instead:

• Check with your utility provider or a rebate specialist
• Submit any required paperwork before starting the project
• Factor the rebate into your ROI calculations

An LED lighting upgrade is a major win for any warehouse—but only if done right. By avoiding these common mistakes, you’ll ensure your investment delivers maximum return in safety, efficiency, and savings.

Need help planning your upgrade? Electro-Matic Visual can conduct a free lighting audit and recommend the right LED solutions for your warehouse.