A logistics operator in the Phoenix Industrial Park had sent an inquiry to Casyoo earlier this year. They said the warehouse that the company is using had obsolete grid-connected high-intensity discharge (HID) lamps. These lamps eventually started getting dim and some even ceased functioning, which led to uneven lighting in places that were important like the loading and unloading area, container yard, and employee parking lot. Considering that in logistics operations night shift and frequent truck transportation are common practice, the lack of even lighting and visibility directly affected safety and performance. Meanwhile, the increasing cost of electricity and the frequent replacement of lamps were increasing operating expenses, prompting the client to find a more sustainable and low-maintenance light solution.
Challenge
Our main challenge was to enhance both visibility and safety at nighttime considerably, without disrupting daily operations or investing in costly civil works. If we want to extend the grid power to the darker corners of the yard, we are required to trench, have new underground cabling and this means longer shutdowns, which our customer wanted to avoid. The new system needed to be able to handle the severe heat, dust and the occasional storms of Phoenix. The client asked us to balance all of this with a clear reduction in energy consumption and maintenance workload.
Solution – Helios Max Solar Street Lights for the Industrial Park Yard
According to the customer requirements, we have offered a complete solar upgrade with our Casyoo Helios Max Series all-in-one solar street lights. And we configured varying watts for various zones. We installed 100W Helios Max on pedestrian access and staff parking, 200W on side loading doors and entrance to the warehouse and 300W on the main truck driveway and container stacks where illumination was at the greatest requirement.
The Helios Max integrates a high-efficiency monocrystalline solar panel, LiFePO4 battery and 6500K LED module in one IP65-rated ABS + PC housing, enabling us to install the fixtures on 5-meter poles without additional drivers or external junction boxes. We coded the built-in smart control system – radar motion sensing system, smart light control and time control – to ensure that the luminaires will be dimmed during quiet periods and automatically increased to full brightness as the trucks or staff approached the yard. This adaptive behavior maintains battery capacity and provides bright and focused light at the time of activity.
The installation was carried out during off-peak hours. As every Helios Max is fully solar-powered, we did not need to trench or install any new wiring, instead we just needed to position the poles, adjust the tilt and orientation and set the timing profiles on-site. The client’s operations continued almost uninterrupted throughout the retrofit.
Result
Having commissioned the system, the warehouse yard experienced a noticeable increase in overall light and its uniformity. Dark areas around dock doors and between rows of containers disappeared, and now drivers can work more easily in aligning trailers, and forklift operators can work well at night. Daylight-white 6500K output provided sharper CCTV images due to security staff testimony of the same.
By replacing the previous grid-tied HID fixtures with solar lights, the client reduced outdoor lighting electricity usage by more than 80%. And the routine lamp and ballast replacements were virtually eliminated. The LiFePO4 batteries employed in Helios Max have a service life of around five years, and the long-life LEDs further reduce maintenance needs. During a brief grid outage caused by a summer storm, our solar lights remained fully operational, which strengthened the client’s confidence in the resilience of the new system.
Featured Product
For this Phoenix project, we selected our Casyoo Helios Max Series all-in-one solar street lights in 100W, 200W and 300W versions. Each fixture uses high-output 5050 SMD LEDs (up to 248 pcs) at 6500K with CRI > 70, powered by a 3.2V LiFePO₄battery pack ranging from 15,000 to 20,000 mAh. A 6V monocrystalline solar panel rated 20–30 W charges the battery during the day and supports up to 12 hours of lighting per night under typical conditions. All components are integrated into a compact ABS + PC body with IP65 protection and an operating temperature range of −20℃ to +50℃, making Helios Max well suited to Phoenix’s harsh climate.
As with all our solutions, we offered OEM/ODM customization for this client, including panel sizing, battery capacity, sensor settings and housing colors, ensuring that the Helios Max system not only met the technical requirements of the industrial park warehouse, but also aligned with their long-term sustainability and branding goals.
