Metal Halide to LED Conversion Chart: Why Industrial Facilities Are Replacing HID Lighting
If your facility still uses metal halide lighting, you’re probably familiar with the same problems many warehouse and factory managers deal with every day.
The lights take several minutes to reach full brightness.
Fixtures begin flickering as they age.
Ballasts fail unexpectedly.
And after a brief power outage, entire areas can remain dark while lamps cool down and restart.
For years, these issues were simply accepted as part of operating an HID lighting system. Today, that’s no longer necessary.
Modern LED high bay fixtures can reduce energy consumption by more than 60%, eliminate ballast maintenance, and provide instant-on performance.
That’s why more warehouses, manufacturing facilities, gymnasiums, aircraft hangars, and distribution centers are replacing metal halide fixtures with LED technology.
The Hidden Costs of Keeping Metal Halide Fixtures
When evaluating a lighting upgrade, many facility managers focus only on fixture cost.
The bigger expense is often the ongoing cost of operating and maintaining an aging HID system.
Common costs include:
- High energy consumption
- Lamp replacements
- Ballast replacements
- Lift rental and labor costs
- Downtime caused by lighting failures
Individually, these costs may seem manageable. Over several years, however, they can become a significant operating expense.
Metal Halide to LED Conversion Chart
The chart below compares a typical 400W metal halide fixture with a 150W LED high bay replacement operating 12 hours per day over a 10-year period.
| Cost Factor | 400W Metal Halide | 150W LED |
|---|---|---|
| Energy Consumption | 17,520 kWh | 6,570 kWh |
| Energy Cost (@ $0.12/kWh) | $2,102 | $788 |
| Lamp Replacements | $300+ | $50 |
| Ballast Maintenance | $400+ | $0 |
| Total Estimated Cost | $2,802 | $838 |
Estimated Savings: $1,964 per fixture over 10 years.
For facilities with dozens or even hundreds of fixtures, the potential savings can be substantial.
A warehouse with 100 fixtures could save nearly $200,000 over the same period through reduced energy use and maintenance costs alone.
Why Ballasts Are One of the Biggest Maintenance Problems
Ask most maintenance teams what causes the most lighting service calls, and ballasts are usually near the top of the list.
As HID systems age, ballasts often cause:
- Flickering lights
- Delayed startup
- Random shutoffs
- Reduced light output
- Complete fixture failure
The challenge becomes even greater in facilities with mounting heights of 20, 30, or 40 feet, where every maintenance visit may require special equipment and labor.
Unlike metal halide fixtures, LED fixtures do not rely on external ballasts. Eliminating the ballast removes one of the most common failure points in the entire lighting system.
How Type B LED Retrofits Reduce Long-Term Costs
One reason many facility owners delay an upgrade is the concern that converting to LED requires extensive rewiring.
In most cases, it doesn’t.
Many industrial LED retrofits use a ballast bypass approach, commonly referred to as a Type B retrofit. The existing branch circuit remains in place while the ballast is removed from the fixture.
For facility owners, the benefit is simple:
- Fewer components that can fail
- Lower maintenance requirements
- Improved system reliability
- Better long-term operating costs
The result is a cleaner and more efficient lighting system without the expense of rewiring the entire building.
Should You Leave Old Ballasts Inside the Fixture?
Some retrofit projects bypass the ballast but leave the old component inside the fixture housing.
While this may save a few minutes during installation, it often creates future problems.
Leaving unused ballasts in place can:
Create Maintenance Confusion
Years later, maintenance personnel may assume the ballast is still active, resulting in unnecessary troubleshooting and longer service calls.
Add Unnecessary Weight
Older HID ballasts can be surprisingly heavy. Removing unused components helps reduce unnecessary weight inside the fixture.
Increase Heat Inside the Fixture
Although no longer part of the operating circuit, unused components can contribute to heat buildup and reduce the overall cleanliness of the installation.
A professional retrofit typically removes unnecessary ballast components and clearly labels the fixture for future maintenance.
How Much Could Your Facility Save?
The savings from an LED upgrade depend on several factors:
- Number of fixtures
- Operating hours
- Utility rates
- Fixture wattage
- Current maintenance costs
Facilities operating multiple shifts often achieve the fastest payback periods because of their higher energy usage.
In many cases, energy savings and reduced maintenance costs allow the upgrade to pay for itself within just a few years.
Ready to See Your Potential Savings?
If you’re dealing with flickering lights, failing ballasts, long warm-up times, or rising energy costs, it may be time to evaluate an LED upgrade.
Our lighting specialists can help you compare your current HID system with modern LED alternatives and estimate:
- Energy savings
- Maintenance savings
- Payback period
- Recommended fixture replacements
Contact us today for a free lighting assessment and customized savings analysis.tly, full-scale electrical overhaul.
