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When procurement managers and facility directors ask whether LED lights raise electricity costs, they're rarely asking about the basic physics. They already know LEDs are more efficient. What they actually want to know is: how much will we save, how fast, and what could go wrong?
This guide answers exactly those questions — with numbers drawn from U.S. Department of Energy (DOE) and ENERGY STAR data, and ROI frameworks applicable to warehouses, offices, and industrial sites operating 10–24 hours a day.
Key Finding (U.S. DOE, 2024)
LED lighting products produce light up to 90% more efficiently than incandescent bulbs. Lighting accounts for 17% of all electricity consumed in U.S. commercial buildings — making it one of the highest-leverage areas for cost reduction.
Source: ENERGY STAR Commercial Lighting & U.S. DOE LED Lighting Overview
The efficiency gap between LEDs and legacy lighting technologies comes down to how each source converts electrical energy into visible light.
Incandescent bulbs operate by heating a tungsten filament until it glows — a process that releases 90% of consumed energy as heat, leaving only 10% as usable light. CFL bulbs are more efficient but still lose roughly 80% of energy as heat.
LEDs work differently. An electrical current passes through a semiconductor microchip, which directly produces photons. Heat that does accumulate is drawn away by a purpose-built heat sink. The result: LEDs convert far more of the input wattage into light output (measured in lumens), achieving significantly higher luminous efficacy.
Practical implication for facility managers: A 400-watt metal halide high-bay fixture in a warehouse can typically be replaced by a 150-watt LED high-bay that delivers equivalent or superior light levels — a 62.5% reduction in wattage per fixture before factoring in controls.
The table below compares the four major commercial lighting technologies across the metrics that matter most to procurement teams. All wattage figures use a standard 60W-equivalent lumen output (approximately 800 lumens) as the basis.
Intellectual honesty matters here. There are scenarios where a poorly managed LED upgrade does not deliver the expected savings — and buyers deserve to understand them upfront.
Replacing a 200W fixture with a 200W LED — instead of the appropriate 80–100W LED equivalent — results in over-lit spaces and unnecessarily high energy consumption. A professional photometric study before procurement prevents this common error.
Uncertified, low-cost LED fixtures may have actual efficacy (lumens-per-watt) far below what marketing materials claim. They also experience early lumen depreciation, meaning light output degrades faster than rated. The DesignLights Consortium (DLC) Qualified Products List is the industry benchmark for verifying commercial LED performance claims.
High-usage facilities — such as cold-storage warehouses or manufacturing plants — can amplify any inefficiency through sheer operating hours. Pairing LED fixtures with occupancy sensors and daylight harvesting controls can add a further 20–40% energy reduction on top of the base LED savings, according to industry retrofit analysis.
Utility rebate programs across the U.S. can cover 20–50% of project costs, dramatically shortening payback periods. Facilities that skip this step are leaving money on the table. ENERGY STAR and the DOE maintain regional incentive databases that commercial buyers should consult before any major procurement decision.
The following scenario estimates are drawn from published DOE case study methodology and commercial retrofit data. They assume U.S. average commercial electricity rates (~$0.12–0.14/kWh as of 2024) and do not include utility rebates, which would further improve all figures.
The Hidden Savings: Maintenance & HVAC
Energy reduction is only part of the picture. Industry analysis of 500+ industrial retrofits shows that maintenance cost elimination and HVAC load reduction together can add 20–40% to total project ROI beyond basic kWh savings. Every watt of heat not produced by a lighting fixture is a watt your cooling system does not have to remove.
A procurement decision at scale requires more than selecting the cheapest fixture with "LED" in the product name. The following checklist reflects best-practice specification criteria for commercial and industrial buyers:
The data is unambiguous. Properly specified LED lighting reduces electricity consumption by 75–90% versus incandescent technology and by 50–60% versus CFL, according to ENERGY STAR and DOE figures. For commercial facilities running lights 12 or more hours per day, the financial case is compelling: most industrial and commercial LED retrofit projects achieve full payback within 1–3 years, with decades of net savings to follow.
The caveats matter too. Savings are maximized when procurement is grounded in proper photometric design, DLC-certified products, and a rebate capture strategy. The difference between a well-executed LED project and a disappointing one is rarely the technology — it's the specification and sourcing process.
Infralumin specializes exclusively as a high-performance LED outdoor luminaires manufacturer — street lights, road lights, and area lighting built for municipal, highway, and industrial environments. With IP66-rated enclosures, 5-year warranties, and fixtures independently certified to IES and DLC standards, our products are engineered for projects where reliability and long-term cost control are non-negotiable.
Talk to Infralumin’s Street Lighting Team → https://infralumin.com/
References & Further Reading
All claims in this article are sourced from peer-reviewed studies, government databases, or accredited industry data. Readers are encouraged to consult primary sources for project-specific guidance.