LED High Bay Replacement for 400W Metal Halide: XJ-HBG150W Project in Germany

Project Location: Germany
Application: Large Industrial Facility
Product Model: XJ-HBG150W-2
Brand: SEEKINGLED

This German project involved a large number of existing metal halide fixtures. The site was operating with 192 units of 400W MH lamps. The lighting grid had clearly been designed years ago, when fixture quantity mattered more than efficiency. By the time we reviewed it, power consumption was high, and maintenance had become an issue.

The initial question from the customer was whether a direct LED replacement was possible. Technically, yes. Practically, it did not make sense.

Rethinking the One-to-One Approach

A one-to-one replacement would have meant installing 192 LED high bays. That would have reduced power per fixture, but it would not have addressed the layout itself. We suggested stepping back and recalculating the entire lighting arrangement instead.

That decision took longer upfront. But it opened the door to reducing both fixture count and total load.

New Lighting Calculation

We ran a fresh lighting calculation based on the actual working plane and mounting height. The result showed that we could meet the required light levels using only 72 units of XJ-HBG150W-2 LED High Bay Light.

At that point, the numbers became very clear.

• Existing system: 192 × 400W = 76,800W
• Proposed system: 72 × 150W = 10,800W

The customer focused heavily on whether fewer fixtures would create dark zones. That was a fair concern. We reviewed uniformity carefully before final approval.

Installation and Layout Change

Installation required removing a significant number of old fixtures. The new layout was more open, with wider spacing than before. That always looks risky on paper, especially to people who are used to dense lighting grids.

Once the XJ-HBG150W fixtures were installed and powered on, the concern faded quickly. Light levels were consistent, and the space felt less cluttered overhead.

After Commissioning

Post-installation measurements confirmed that the lighting levels met the planned targets. From an energy standpoint, the reduction was substantial—around 86% compared to the previous system.

From my perspective, the most important part of this LED High Bay Replacement for 400W Metal Halide project was not the savings figure itself. It was the decision to challenge the existing layout instead of copying it. That choice defined the outcome.

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