LED vs Metal Halide: The Complete Replacement Guide
Compare LED and metal halide lighting. Covers energy savings, lumen equivalents, warm-up time, CRI, lifespan, and how to choose the right LED replacement wattage.
Metal halide (MH) fixtures were the standard for commercial lighting for decades. Today, LED replacements deliver better light, use 50-70% less energy, and last 5× longer. Here's your complete replacement guide.
LED vs Metal Halide: Side-by-Side
| Feature | Metal Halide | LED |
|---|---|---|
| Efficacy | 60-90 lm/W | 130-160 lm/W |
| Lifespan | 10,000-20,000 hrs | 50,000-100,000 hrs |
| Warm-up time | 5-15 minutes | Instant on |
| Re-strike time | 10-20 minutes | None |
| CRI | 65-70 | 80-90 |
| Lumen depreciation | 40% at half-life | 10% at half-life |
| Contains mercury | Yes | No |
| Dimmable | Rarely | Yes (0-10V) |
Wattage Replacement Chart
| Metal Halide | LED Replacement | Energy Savings | Auvolar Product | Price |
|---|---|---|---|---|
| 100W MH | 40-50W LED | 50-60% | Wall Pack 50W | $55 |
| 150W MH | 50-70W LED | 53-67% | Flood Light 50W | $45 |
| 175W MH | 60-80W LED | 54-66% | Wall Pack 80W | $72 |
| 250W MH | 80-100W LED | 60-68% | Area Light 100W | $129 |
| 400W MH | 150-200W LED | 50-63% | UFO High Bay 150W | $89 |
| 1000W MH | 300-400W LED | 60-70% | Flood Light 400W | $265 |
Real Lumen Comparison
A new 400W metal halide produces about 36,000 lumens. But:
- Ballast loss: -15% → 30,600 lumens
- After 6 months: -20% → 24,480 lumens
- After 2 years: -35% → 18,720 effective lumens
Auvolar's 150W UFO High Bay produces 22,500 lumens consistently for 100,000+ hours — delivering MORE usable light than a 400W MH after its first year.
Hidden Costs of Metal Halide
Beyond energy, MH fixtures carry ongoing costs:
- Re-lamping: $50-$200 per fixture every 2-3 years (bulb + labor + equipment rental)
- Ballast replacement: $30-$100 every 3-5 years
- Mercury disposal: Special handling required by EPA regulations
- Productivity loss: 5-15 minute warm-up means lights can't be turned off during breaks
- Insurance: Higher premiums due to fire risk from hot fixtures
The Business Case
50-fixture warehouse retrofit (400W MH → 150W LED):| Metal Halide (Annual) | LED (Annual) | |
|---|---|---|
| Energy | $14,400 | $5,400 |
| Maintenance | $3,500 | $0 |
| Total | $17,900 | $5,400 |
| Savings | $12,500/year |
Fixture cost: 50 × $89 = $4,450. DLC rebate: 50 × $60 = -$3,000. Net: $1,450. Payback: 6 weeks.
Two Retrofit Approaches
1. Complete Fixture Replacement (Recommended)
Remove old MH fixture, install new LED fixture. Best light quality, longest lifespan, highest rebate eligibility.
2. LED Corn Bulb Retrofit
Keep existing fixture housing, replace MH bulb with LED corn bulb. Lower upfront cost but shorter lifespan and may not qualify for DLC rebates.
For most applications, complete fixture replacement with Auvolar LED fixtures offers the best long-term value. Contact us for a free energy audit and retrofit quote.
Need Help With Your Lighting Project?
Auvolar provides free lighting design, photometric layouts, and rebate assistance for commercial projects.