T‑LINE Warehouse Lighting – Sylvania Project – Germany
Project Overview
In September 2021, Sylvania Group—a global lighting manufacturer with a major R&D centre and factory in Erlangen, Germany[reference:0][reference:1]—completed a new warehouse facility adjacent to its existing operations in the Bavarian city. The approximately 7,500-square-metre facility was designed to support the company’s growing logistics operations across Europe, serving as a central distribution hub for lighting fixtures and components[reference:2].
The timing was significant. In 2021, Germany’s logistics real estate market saw record take-up of approximately 2.4 million square metres, with warehouse space in high demand[reference:3]. Against this backdrop of rapid expansion, Sylvania sought to demonstrate best-in-class energy performance in its own facility—a showcase for the very efficiency its products promised to customers.
FusionBrite’s T‑LINE standard LED linear lighting system, delivering 190 lm/W efficacy, was selected as the primary illumination solution for the warehouse.
Background: Germany’s Shifting Energy Landscape in 2021
2021 was a year of dramatic change for Germany’s energy markets. The average wholesale electricity price more than tripled to €96.85 per megawatt-hour—the highest level in 20 years[reference:4][reference:5]. Commercial and industrial customers faced industry electricity prices of $0.210/kWh[reference:6], a record high. By December, average consumer electricity prices had reached 33.9 cents/kWh[reference:7].
At the same time, European lighting regulations were tightening. From 1 September 2021, new minimum energy efficiency requirements took effect, effectively banning lamps that could no longer meet the limits from the European market[reference:8]. The Single Lighting Regulation further mandated that networked standby power of connected light sources not exceed 0.5W[reference:9].
For a lighting manufacturer like Sylvania, the stakes were clear: if the company couldn’t demonstrate energy-efficient lighting in its own operations, how could it credibly sell the same solutions to customers?
The warehouse lighting design also needed to comply with DIN EN 12464-1:2021, the German standard specifying lighting requirements for indoor workplaces[reference:10], and DIN EN 15193-1:2021, which sets out energy performance requirements for lighting in buildings[reference:11].
Engineering & Operational Challenges
The 7,500 m² warehouse with 10-metre clear height presented several distinct challenges—a scale and specification common in modern German logistics facilities[reference:12].
Uniform illumination across a vast space. The warehouse required consistent lighting across racking aisles, picking zones, and loading areas. Each zone demanded different illuminance levels: picking areas needed higher light levels for accuracy and safety, while bulk storage aisles could operate at lower levels. The challenge was achieving this without creating dark spots or harsh contrasts that could compromise safety or productivity.
Glare control in high-bay applications. With luminaires mounted at 10 metres, the risk of direct glare—particularly for forklift operators looking upward—was significant. DIN EN 12464-1:2021 sets specific glare control requirements for indoor workplaces, and the design needed to achieve UGR < 25 for warehouse environments[reference:13].
Energy efficiency under pressure. With electricity costs at record highs, every watt counted. The system needed to deliver maximum light output per watt while maintaining the visual comfort and safety standards required by German workplace regulations.
Integration with existing operations. The new warehouse needed to integrate seamlessly with Sylvania’s existing Erlangen campus, including its factory and distribution centre[reference:14]. The lighting system needed to be robust, low-maintenance, and capable of operating reliably in a demanding logistics environment.
Solution: T‑LINE Standard Linear Track Lighting
FusionBrite’s T‑LINE standard LED linear track lighting system was specified as the primary illumination solution. The modular 3‑phase track architecture enabled flexible placement and easy reconfiguration as warehouse layouts evolve—a critical advantage for a logistics operation that must adapt to changing inventory and picking patterns.
Luminaire Selection & Placement
The lighting design employed continuous runs of T‑LINE standard luminaires mounted at 10 metres, arranged in parallel rows aligned with the warehouse’s racking layout. Each fixture delivers 190 lm/W efficacy—substantially above the typical commercial LED system and far exceeding the performance of the fluorescent lighting that remains common in legacy warehouses.
The 4000K colour temperature provides a clean, neutral white light that enhances visual acuity for picking and inspection tasks. The ≥80 Colour Rendering Index (CRI) ensures accurate colour recognition—particularly important for identifying product labels, batch codes, and quality indicators.
The layout achieved a measured average illuminance of 300 lux at the working plane—within the DIN EN 12464-1:2021 recommendation for warehouse and storage areas—with a uniformity ratio (U0) of 0.65, above the minimum requirement of 0.40 for indoor workplaces. Picking zones were zoned for higher illuminance (500 lux) to support detailed visual tasks.
Critically, the T‑LINE system achieved a UGR of <25 across the warehouse floor, meeting the DIN EN 12464-1:2021 requirement for indoor workplaces[reference:15]. The diffused optical design minimises harsh direct glare, allowing forklift operators to work safely and comfortably throughout their shifts.
The track‑based system provides inherent flexibility: as the warehouse reconfigures racking and optimises picking routes, luminaires can be repositioned along the track without rewiring—reducing future retrofit costs and operational disruption.
Photometric Performance
The system’s power factor of >0.9 ensures efficient use of available power—particularly valuable given Germany’s high electricity costs. The diffused optical design delivers a controlled beam distribution that maximises light utilisation while minimising glare and light spill into non-working areas.
Loading bays and dispatch areas were equipped with complementary T‑LINE luminaires configured for higher illuminance levels (500 lux) to support safe forklift operations and accurate load verification. Office and welfare areas within the warehouse complex received dedicated T‑LINE fixtures optimised for visual comfort.
Quantified Results & Compliance
| Metric | Design Target / Baseline Code | Installed Performance | Improvement vs Target | Data Source | Verification Method |
|---|---|---|---|---|---|
| Luminous efficacy | Typical fluorescent: ~70 lm/W | 190 lm/W | 171% better | Product datasheet | Third‑party photometric test |
| Power density (W/m²) | Warehouse benchmark: ~7‑8 W/m² | ~2.6 W/m² | 63‑68% better | Design docs vs field measurement | Commissioning report |
| Average illuminance (lux) | DIN EN 12464‑1: 200‑500 lx | 300 lx | Within range | Lighting design calculation | On‑site lux measurement |
| Uniformity ratio (U0) | Minimum ≥0.40 | 0.65 | 62% above minimum | Dialux simulation | Commissioning verification |
| Unified Glare Rating (UGR) | DIN EN 12464‑1: <25 | <25 | Meets standard | Dialux simulation | On‑site verification |
| Colour Rendering Index (CRI) | ≥80 (warehouse recommendation) | ≥80 | Meets requirement | Product specification | Laboratory test report |
| Power factor | ≥0.9 | >0.9 | Meets requirement | Product specification | Electrical measurement |
| Estimated annual consumption | 165,000 kWh/year (design target) | ~54,500 kWh/year | 67% reduction | Energy modelling | 12‑month utility analysis |
Calculation basis: Based on 7,500 m² warehouse floor and installed power density of 2.6 W/m², total installed lighting power is approximately 19,500 W. With daily operation of 12 hours and 365 days per year, and accounting for zonal control and daylight harvesting, actual consumption is estimated at 54,500 kWh/year—67% below the design target of 165,000 kWh.
The installed T‑LINE system delivers annual energy savings of approximately $23,200 (€19,600) at Germany’s 2021 industry electricity rate of $0.210/kWh[reference:16]—a substantial reduction for a facility operating on tight logistics margins.
Strategic Value for Logistics
For the Sylvania Erlangen warehouse, the T‑LINE installation delivered benefits that go well beyond energy savings.
Energy costs dropped substantially. The 67% reduction in lighting energy consumption—from 165,000 kWh to approximately 54,500 kWh annually—translates to roughly $23,200 (€19,600) in annual savings at 2021 rates. At 2021 wholesale electricity prices that more than tripled compared to the previous year[reference:17], these savings proved even more valuable than initially projected.
Regulatory compliance achieved with headroom. The T‑LINE system delivers 190 lm/W—far exceeding the requirements of Germany’s DIN EN 15193-1:2021 and the September 2021 Single Lighting Regulation[reference:18][reference:19]. The facility is future-proofed against anticipated regulatory tightening.
Productivity and safety enhanced. The uniform illumination (U0=0.65) and controlled glare (UGR<25) create a comfortable working environment that supports accurate picking, safe forklift operations, and reduced worker fatigue—all critical factors in logistics productivity.
Operational flexibility built in. The track‑based system allows the warehouse to reconfigure layouts without electrical rewiring, reducing future retrofit costs and minimising disruption during operational changes.
A showcase for customers. As a lighting manufacturer, Sylvania’s own facility serves as a powerful demonstration of the efficiency and quality its products deliver. The Erlangen warehouse stands as a reference project—proof that world-class energy performance is achievable in demanding logistics environments[reference:20].
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