176 high bays, a third less lighting energy for Toll
Toll runs the Mars distribution centre as a round-the-clock pick, pack and despatch operation. Every high bay across the warehouse was upgraded to sensor-controlled LED, with racking full and forklifts moving.
Walk the warehouse floor.
176 high bays across the racking aisles, docks and staging areas, upgraded without pausing pick and despatch.
- Every high bay fitted with occupancy and daylight sensors
- Sensor settings adjustable from the ground with the remote provided
- Decommissioning, recycling and VEEC paperwork handled end to end
Warehouse light that switches itself off.
The warehouse was drawing an estimated 63,898kWh a year on high bay lighting alone — about $15,974 at the tariff used in the assessment. The existing high bays were LED, but every one of them ran at full output whenever the lights were on.
In a distribution centre most of that light is wasted. Racking aisles sit empty between picks, dock areas fill with daylight when the roller doors are open, and the whole floor stays lit through quiet overnight periods.
The brief was to cut that waste without dropping light levels for pickers and forklift traffic, so the upgrade focused on control: sensor-equipped high bays that dim and switch on demand, area by area.
Every high bay, now on sensors.
The warehouse high bays were replaced one for one with sensor-equipped units — same coverage, same light on the floor, controlled per fitting.
Every high bay went in with occupancy and daylight sensors active, so aisles dim back when there is enough natural light and drop away when nobody is picking in them.
Same light on the floor, a third off the load.
Estimated high bay consumption falls from 63,898kWh to 41,600kWh a year — a saving of 22,298kWh, driven almost entirely by control rather than raw wattage.
A year off the warehouse's high bay lighting consumption.
Lighting electricity cost drops from $15,974 to $10,400 a year.
Cumulative lighting spend of $104,000 with the upgrade against $170,144 without it, investment included.
Victorian Energy Efficiency Certificates created against the upgrade.
Figures taken from the lighting upgrade proposal prepared for this site, calculated on the audited quantities and wattages of the existing high bays and their assumed operating hours.
Turn-key, from audit to certificates.
Lighting audit
Every high bay counted and its wattage and run hours recorded, to establish a real baseline and a return-on-investment figure.
Lighting design
Fitting selection and sensor strategy set so light levels hold for pickers and forklift traffic while control does the saving.
Staged install
Project management, labour, equipment hire and waste management handled by AEU, sequenced around pick, pack and despatch shifts.
Recycling & VEECs
Old fittings decommissioned and recycled, with recycling certificates and all evidence prepared for VEEC creation.
What the project included
As quotedA live warehouse, relit aisle by aisle.
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All financial and energy figures shown on this page are estimates taken from the lighting upgrade proposal prepared for this site. They are modelled projections, not measured or audited results, and do not represent actual savings achieved. Calculations are based on the audited quantities and wattages of existing fittings and assumed operating hours, and will differ if actual quantities, wattages or run hours vary. Actual consumption, bill reductions and return on investment will vary with operating hours, sensor settings, site conditions, equipment performance, and changes in tariffs and network charges. Nothing on this page is a guarantee of performance or savings, financial advice, or an offer. System specifications, warranties and inclusions reflect the proposal as quoted and may have changed at installation. Certificate values, including VEECs, are subject to market forces and eligibility, and any discount will alter if quantities or existing wattages differ from those detailed in the proposal. Speak to us for figures modelled on your own site and bills.