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How much could you save by switching to LED lighting?

How much could you save by switching to LED lighting?

Over the past few months, we’ve received a number of enquiries via our social media channels on Facebook and Twitter asking why customers should change to LED lighting given that the initial investment in warning and work lighting is higher than traditional models.¬† Well, we carried out an investigation into long-term gain versus the short-term pain of that initial investment and the results were startling!

In fact, when we looked at the benefits of using Dun-Bri’s own-brand LED beacons and work lights versus halogen bulb flashing beacons and worklamps we figured out that there were actually huge time and cost-savings as well as massive reductions in CO2 emissions over a period of a few years…



How we’ve worked out our calculations…


Experience shows that the actual bulbs, as well as whole flashing beacons and work lights have the following average replacement rates on a fleet:

  • Bulbs – twice a year,
  • Worklamps – once every two years,
  • Beacons – once a year


Now obviously this is different for different industry sectors such as plant hire which experience high amounts of mechanical and accidental damage.  It should also be noted that this is based on the working time of each product of 6 hours per day.

Then we have calculated the cost of traditional halogen beacons, work lights and bulbs – based on the average end-user costs;


Halogen lighting LED lighting
Worklights £18 each £25 each
Beacons £25 each £60 each
Bulb £3 each




Halogen vs. LED lighting costs


These cost calculations are based on a vehicle with 2 beacons to be ‘Chapter 8’ compliant, and 3 work lights.¬† This ensures visibility to the rear and sides of a vehicle where you are most likely to be working.¬† Please note that in the case of LED lighting, labour costs are only incurred when converting your existing fleet.

If you specify LED lighting products in newly specified and built vehicles, then you can extend the benefit of potential savings in full from the outset.


Halogen lighting LED lighting
Labour costs (per vehicle) Labour costs (per vehicle)
Replacement cost of worklights
(1.5 worklights x 0.5h x £40 p/h fitting cost)
£30 Replacement cost of worklights*
(3 worklights x 0.5h x £40 p/h fitting cost)
Replacement cost of beacons
(2 beacons x 0.5h x £40 p/h fitting cost)
£40 Replacement cost of beacons*
(2 beacons x 0.5h x £40 p/h fitting cost)
Bulb change for worklights
(3 worklights x 0.25h x 2 changes per year x £40 p/h fitting cost)
Bulb change for beacons
(2 beacons x 0.25h x 2 changes per year x £40 p/h fitting cost)
Total annual labour cost (per vehicle) £170 Total annual labour cost (per vehicle) £100
Annual material costs (per vehicle) One-off material costs (per vehicle)
Halogen worklights
(£27 product cost + £18 for bulbs)
£45 LED worklights
(3 worklights @ £25)
Halogen rotating beacons
(£50 product cost + £12 for bulbs)
£62 LED beacons
(2 beacons @ £60)
Total annual material costs (per vehicle) £107 Total procurement cost (per vehicle) £195
Total costs Total one-off costs
Labour costs £170 Labour costs £100
Material costs £107 Procurement costs £195
Halogen option £277 LED option £295




Vehicle lifetime comparison


If we then multiply that by an average service vehicle life of 8 years, you can see how the costs of halogen vs. LED offer you a continuing saving;


1 2 3 4 5 6 7 8 Total
Halogen costs per year £277 £277 £277 £277 £277 £277 £277 £277 £2,216
LED costs per year £295 £0 £0 £40 £60 £0 £40 £60 £495
Maintenance costs savings per vehicle, per year -£18 £277 £277 £237 £217 £277 £237 £217 £1,721


Based on our calculations, you’ve already saved money by the second year after the installation of LED lighting.¬† But what other benefits are there?


Fuel savings due to the use of LED lighting


Another significant benefit of LED lighting over more traditional models is the reduction of fuel consumption when they are switched on.  If you work out the amount of time they are switched on (6 hours a day), over the course of 200 working days per year here are the results;


Halogen LED
2x beacons power consumption (nominal) 140 Watts 40 Watts
3x worklights power consumption (nominal) 210 Watts 54 Watts
Total consumption 350 Watts 94 Watts
kWh per vehicle per year saved
(350W – 94W) x 6 x 200/1,000
307.2 kWh


If you then wanted to translate this into the amount of diesel you could potentially save each year;


Degree of efficiency of a modern diesel engine 45%
Degree of efficiency of an alternator 75%
Electrical energy generated by diesel
(1 litre generates 3.375 kWh)
10 kWh / litre
Diesel saved (in litres)
307.2 kWh / 3,375 kWh
91 litres approx.




Savings potential on a fleet of 100 vehicles


Taking account of all of the information we’ve seen so far, if you multiply the results over a fleet of one hundred vehicles here are the results including those savings on CO2 emissions that we mentioned earlier;


1 2 3 4 5 6 7 8 Total
Annual cost for halogen £27,700 £27,700 £27,700 £27,700 £27,700 £27,700 £27,700 £27,700 £221,600
Annual cost for LED £29,500 £0 £0 £4,000 £6,000 £0 £4,000 £6,000 £49,500
Maintenance cost savings -£2,500 £27,700 £27,700 £23,700 £21,700 £27,700 £23,700 £21,700 £172,100 saving
Fuel savings 9,100l 9,100l 9,100l 9,100l 9,100l 9,100l 9,100l 9,100l 72,800 litres
CO2 savings* 24,388kg 24,388kg 24,388kg 24,388kg 24,388kg 24,388kg 24,388kg 24,388kg 195,104 kg

*CO2 emissions are weighted at 2.68kg per litre of diesel burnt.


So that’s a saving purely on fuel on today’s prices of ¬£84,448 over the course of 8 years and that’s before you even look at the other benefits!



Find out more and buy…

You can log in to your Dun-Bri account using our Online service to purchase LED flashing beacons and LED lighting, or to find out more information including how to open an account with us, please call us on 01763 274185, email us at or visit your local branch!



The data contained within this document is non-binding and is based on average values and general technical assumptions.  The use of such data is purely for support purposes only and no liability will be accepted.

Average information – Dun-Bri Fit, Hella
CO2 emissions data – Exeter University ( (View source)
Diesel fuel price – 116.00p per litre, The AA (August 2017 data) ( (View source)

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