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Case study · Networked lighting controls

Six aisles, one picker

118,000 sq ft distribution warehouse in Brooklyn — 186 high bays, already LED, full output for the whole two-shift day.

Distribution warehouse · Brooklyn, NY · 11 zones

Warehouse control zone planA distribution warehouse with a dock, cross aisle, offices and six racking aisles each on its own control zone. A picker works aisle three at full output with its neighbours ramped, then crosses to aisle four and the zones hand off; the rest sit at ten percent throughout.DISTRIBUTION WAREHOUSE — ONE ZONE PER AISLEDock — 6 doorsCross aisleRackingOfficesStagingAisle 1 — 10%Aisle 2 — 40%Aisle 2 — 10%Aisle 3 — 100%Aisle 3 — 40%Aisle 4 — 40%Aisle 4 — 100%Aisle 5 — 10%Aisle 5 — 40%Aisle 6 — 10%100 / 40 / 10% outputHigh bay + controllerWireless meshControl deviceOne picker lights one aisle. Five of six sit near dark at any moment — that is the whole case.
Figure 1 — One occupied aisle at full, neighbours ramped, the rest at 10%.
Schedule

Zone by zone

Eleven zones covering racking, cross aisle, dock, staging and offices.

ZoneSpaceHrs/yrControlWhy
Z-1 – Z-6Racking aisles ×66,24010% standby, adjacent-aisle rampOne picker, one aisle at a time
Z-7Cross aisle6,24030% standby, occupancy to fullContinuous travel path
Z-8Dock, 6 doors3,600Scheduled + occupancyActive only during shifts
Z-9Staging and packing6,240Occupancy + skylight dimmingDaylit; intermittent work
Z-10Offices2,600Occupancy, daylight, scheduleStandard hours
Z-11Restrooms6,240Occupancy, full offNo standby needed
Commissioned

Sequence of operations

How each zone is programmed.

SpaceSequenceNote
Racking aisles ×610% standby · adjacent-aisle rampOne aisle at a time
Cross aisle30% standby · occupancy to fullContinuous travel path
Dock + stagingshift schedule · skylight dimmingOff between shifts
After hoursauto-off · supervisor overrideNothing left on overnight
Calculated

Annual impact

89,700kWh avoided / yr
$22,425saved / yr at $0.25/kWh
35.3 t
CO₂ avoided / yr
≈3,970
gallons of gasoline equivalent
≈590
tree seedlings grown 10 years

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