Maximize Throughput.
Minimize Downtime.
Stop compromising between safety and energy costs.
Yuanhui delivers specialized Linear Aisle Optics and Smart Sensing Networks designed specifically for High-Bay Logistics. Achieve 200 Lux on the floor, 500 Lux on vertical labels, and cut your energy bill by 75% compared to Metal Halide legacy systems.
Verified for 24/7 operations in DHL, FedEx, and Cold Chain facilities worldwide.
Why “Generic” High Bays Fail in Logistics
A warehouse is not just a big room; it is a precision instrument for moving goods. Standard “UFO” round high bays, while cheap, are optically unsuited for rectangular aisles. They create the “Zebra Effect”—bright hot spots on the top shelves and dangerous dark shadows on the floor.
Furthermore, in a facility with 12-meter ceilings, maintenance is not just a cost; it is a disruption. Changing a single failed driver requires renting a scissor lift, blocking an active aisle, and halting picking operations for hours. This indirect cost often exceeds the price of the fixture itself.
Yuanhui engineers lighting solutions to deliver the “3-Zero Performance Standard”:
01. Zero Maintenance
The Problem: Cheap capacitors dry out in the heat near the roof (often +45°C).
Our Solution: We use industrial-grade Rubycon capacitors rated for 105°C and an oversized heatsink design. Rated L80B10 @ 50,000 hours, meaning 5+ years of 24/7 operation with zero bulb changes.
02. Zero Shadows (Vertical Lux)
The Problem: Forklift drivers can’t read barcodes on bottom racks due to shadows.
Our Solution: Specialized 30°x70° Linear Optics project a “Knife-Edge” beam that washes the entire vertical rack face with uniform light, reducing picking errors by up to 30%.
03. Zero Waste (Smart Control)
The Problem: Lighting empty aisles 24/7 burns 40% of your energy budget.
Our Solution: Integrated Zigbee/Microwave sensors create a “Follow-Me” network. Lights stay at 10% standby and only ramp to 100% when a forklift enters the zone.
Compliance is Non-Negotiable
Lighting levels directly impact worker safety, insurance liability, and operational speed. We design every project strictly according to EN 12464-1 (Europe) and OSHA/IESNA (USA) standards. Below are the critical targets we guarantee in our simulations:
| Zone / Area | Target Lux (Em) | Uniformity (U0) | Glare Limit (UGR) | Engineering Rationale & Risk |
|---|---|---|---|---|
| Loading Docks | 150 – 200 Lux | 0.40 | < 25 | Safety Critical. High traffic of trucks and pedestrians. The transition from bright outdoors to indoors must be managed to prevent “temporary blindness” (adaptation time). IP65 rating required for exterior overhangs. |
| Packing & Dispatch | 300 – 500 Lux | 0.60 | < 19 | Precision Task. High CRI (>80) is mandatory for color coding verification. Shadows must be eliminated to prevent shipping errors. UGR<19 prevents eye fatigue for stationary workers. |
| High-Rack Aisles | 200 Lux (Floor) | 0.50 | < 22 | Vertical Illuminance (Ez). The floor lux is secondary; the lux on the rack face at 10m height is primary. Drivers must scan labels without adjusting their position. |
| Open Marshalling | 200 Lux | 0.50 | < 25 | General Orientation. Requires wide beam angles (90° or 120°) to ensure coverage between stacked pallets. Avoid “cave effect” by ensuring some uplight component. |
01. Optical Engineering: The “Rectangular” Physics
Most LED manufacturers take a standard round “UFO” High Bay, designed for open factories, and try to sell it for warehouse aisles. This is geometrically inefficient.
A standard 120° conical beam throws light in a circle. If your aisle is 3 meters wide, approximately 40% of that light lands on the top of the racking shelves. This is “stray light”—energy you pay for but never use. It does not help the worker see the floor or the label.
The Yuanhui Linear Advantage: We utilize specialized Polarized Polycarbonate Lenses. These lenses refract the light source into a precise rectangular beam pattern (typically 30°x70° or 60°x90°).
- ✓ 95% Utilization: The beam width matches the aisle width.
- ✓ Vertical Wall Wash: Light is directed sideways onto the racks, not just down.
- ✓ Reduced Wattage: A 50W Linear light often replaces a 100W Round light while delivering more useful lux.
Fig 1: Left – Round Beam Wasted on Shelf Tops. Right – Linear Beam Focused on Aisle.
02. Thermal Stratification: Surviving the Roof Heat
Heat rises. In a warehouse, if the floor temperature is 25°C, the temperature at the roof (15 meters up) can easily reach 45°C or 50°C due to thermal stratification and lack of ventilation. This is the “Death Zone” for standard electronics.
Standard LED drivers are rated for Ta (Ambient Temperature) of 40°C. Operating them in a 50°C environment reduces their lifespan by 50% for every 10°C rise. Electrolytic capacitors dry out, causing flickering and failure.
The Yuanhui “Through-Hole” Chassis: Our Linear High Bay features a strategic air gap between the LED engine and the driver compartment. As the LEDs heat up, they create a natural convective updraft (Chimney Effect), pulling cool air from below through the fixture center.
Result: We lower the Driver Case Temperature (Tc) by 15°C compared to solid housings, allowing us to confidently offer a 5-Year Warranty even for installations in non-air-conditioned tropical warehouses.
03. The Brains: Zigbee Mesh & Microwave Sensing
Manual switching is obsolete. Infrared (PIR) sensors are unreliable at heights above 8 meters (thermal signal weakens). Yuanhui deploys 5.8GHz Microwave Sensors which penetrate dust and detect volume changes, offering reliable detection up to 15m height.
Scenario A: The “Follow Me”
Sensors talk to each other via Zigbee. As a forklift enters Aisle 1, the lights in Aisle 1 ramp to 100%, and Aisle 2 pre-lights to 50%, ensuring the driver never enters a dark zone.
Scenario B: Daylight Harvesting
For warehouses with skylights, internal photocells measure ambient light. If the sun provides 300 Lux, the LED driver automatically dims output to 0%, saving 100% energy during noon.
Scenario C: Heat Mapping
(Advanced) The system records occupancy data. Facility managers can see which aisles are used most frequent and optimize stock placement to reduce travel time.
Designed for Rapid Deployment
01. Suspension Chain
Classic V-Hook mounting. Ideal for retrofit projects replacing old metal halide lamps. Compatible with standard jack chains.
02. Surface Mount
Adjustable brackets allow fixing directly to ceiling beams or walls. Perfect for low-bay mezzanines or tilt-up concrete walls.
03. Trunking Rail
Tool-less mechanical and electrical connection to existing trunking rails. Reduces installation time by 40% in new builds.
The Financial Case: CAPEX vs. OPEX
Switching to Yuanhui LED is not an expense; it is an investment with a guaranteed yield. A typical warehouse retrofit pays for itself in 9 to 14 months.
Case Study: 20,000m² Distribution Center
11 Mos
Average Payback Period (ROI)
240 Tons
Annual CO₂ Footprint Reduction
Get Your Custom ROI ReportProven in the Field
DHL Logistics Hub, Germany
Challenge: Replacing 500W HPS lamps in 14m high aisles. Glare complaints from drivers.
Solution: Installed 150W Linear High Bays with 60×90° lenses and UGR<19 diffusers.
Result: 300 Lux on floor, Zero glare complaints, 65% Energy saving.
Cold Chain Facility, Australia
Challenge: High failure rate of fluorescent tubes at -25°C. High maintenance cost.
Solution: IP66 Tri-proof lights with Cold-Start Drivers and Breather Valves.
Result: Instant start-up, Zero failures in 3 years.
Engineering FAQ
What is the difference between Lens and Reflector?
Reflectors (aluminum cups) are older technology that rely on bouncing light. They often lose 15-20% efficiency due to absorption and cannot precisely control the beam edge. Lenses (Polycarbonate/PMMA) use total internal reflection (TIR) physics to guide light with 95% efficiency. For warehouses, Lenses are superior because they can create precise rectangular shapes (aisle beams) that reflectors physically cannot achieve.
Do I need Emergency Lighting in the warehouse?
Yes. BS 5266 and local fire codes strictly require emergency lighting along escape routes and in open areas (Anti-Panic lighting, usually 0.5 Lux). Yuanhui offers integrated EM Kits (LiFePO4 Battery) inside our Linear and Tri-proof fixtures. They provide 3W-8W output for 3 hours during a power outage, eliminating the need to install separate, ugly emergency bulkheads.
What Color Temperature (CCT) is best for logistics?
We recommend 5000K (Cool White) for general logistics. Studies show it promotes alertness and improves contrast for reading labels compared to 4000K. However, for 24-hour manned shifts, 4000K might be preferred to reduce eye strain over long periods. We offer CCT Switchable versions (3000K/4000K/5000K) so you can decide on-site.
How do you prevent moisture in Cold Storage lights?
The biggest killer in cold storage isn’t the cold; it’s the vacuum effect. When a light turns off, it cools down, creating negative pressure that sucks in moist air through the cable gland. We use a specialized ePTFE Membrane Breather Valve. This allows air molecules to equalize pressure but blocks water molecules (IP68), keeping the internal driver dry forever.
