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Custom T8 LED Tube with G5 Pins for Supermarket Lighting Project
Case Snapshot
- Buyer Type
- Electrical Contractor
- Application
- Commercial Lighting, Retail Lighting
- Published
- May 5, 2026
Client Background
The project context behind the customization.
The customer was a European electrical contractor responsible for a supermarket chain lighting retrofit project. The existing installation used 54W T5 fluorescent tubes with G5 lamp sockets and traditional ballasts. The contractor needed an LED replacement that could reduce energy use while fitting the existing fixture structure. A standard T8 LED tube was not suitable because it used larger G13 pins and a longer 5ft body. The customer required a project-ready tube that matched the T5 socket position, lamp length, and brightness expectation.
Visual Documentation
Project gallery
Customization Scope
What we customized and why it mattered
Key Custom Points
01
G5 Pin End Cap: T8 tube end cap customized to fit existing T5 G5 lamp sockets.
02
Tube Length: Body length adjusted from standard 1512mm T8 to 1462mm retrofit size.
03
Brightness Target: High-brightness SMD LEDs selected to reach about 2300lm per tube.
04
Ballast Removal: Tube configured for retrofit after removing the traditional fluorescent ballast.
05
Project Quantity: First production order supported 1,525 pcs after sample confirmation.
Why This Approach Worked
Engineering Approach
Solution provided
VST Lighting provided a customized 25W T8 LED tube for direct retrofit after removing the traditional ballast. The core customization was a G5 pin end cap designed to fit the existing T5 lamp socket instead of the standard G13 T8 end cap. The tube length was adjusted from the common 1512mm 5ft T8 format to match the existing 1462mm T5 fluorescent tube size. High-brightness SMD LEDs were used to reach about 2300lm per tube, supporting the supermarket’s lighting requirement while reducing power from 54W to 25W per lamp. This was a deep customization case because it required end cap tooling, length adjustment, LED configuration review, electrical retrofit confirmation, and sample validation before bulk production. VST supported tooling, first samples, and the first mass order based on the confirmed project requirement.
How We Delivered
Delivery process
01
Requirement Review
VST reviewed the existing T5 lamp size, G5 socket, ballast removal plan, and brightness target.
02
Custom Structure Design
The T8 tube end cap was redesigned with G5 pins and adjusted to the required retrofit length.
03
Tooling and Sample Build
Tooling and first samples were completed for mechanical, electrical, and brightness confirmation.
04
Sample Confirmation
The customer checked socket fit, tube length, installation method, and lumen output before bulk production.
05
First Order Production
VST produced the first 1,525 pcs according to the approved sample and confirmed specification.
Results & Outcomes
What the buyer gained from this custom project
The customized LED tube allowed the contractor to retrofit the supermarket’s existing T5 fluorescent fixtures without replacing the complete fixture housing. By changing the T8 end cap to G5 pins and adjusting the length, the product matched the original socket and lamp space. The 25W LED tube replaced the 54W T5 fluorescent tube after ballast removal, supporting more than 58% energy reduction at lamp level. Sample development helped confirm the mechanical fit, brightness output, and retrofit method before the first order. The case reduced installation uncertainty for the contractor and gave the project a clearer supply path for follow-up replacement
Power Reduction: 25W LED tube replaced existing 54W T5 fluorescent tube.
Energy Saving: More than 58% lamp-level energy reduction after ballast removal.
Luminous Output: About 2300lm per customized LED tube.
Fit Result: G5 pins and 1462mm length matched the existing T5 fixture requirement.
First Order Quantity: 1,525 pcs supplied for the initial supermarket retrofit order.
Risk Assessment
Commercial risk overview
Moq
1,000 pcs
Lead Time
30 days for tooling and first samples; 20 days for the first 1,525 pcs order after sample confirmation.
Sampling Support
VST Lighting supported first sample development to confirm the G5 pin end cap, 1462mm tube length, LED brightness, wiring method after ballast removal, and installation fit in the existing T5 fixture. Sampling was important because the retrofit depended on both mechanical socket compatibility and lighting output.
Supply Stability
After sample approval, VST used the confirmed tube length, G5 end cap structure, LED configuration, and production reference as the basis for bulk supply. For repeat orders, stable supply were delivered on controlled end cap materials, approved samples, packaging records, and clear communication before any component or specification change.
Full Case Notes
Custom T8 LED Tube with G5 Pins for Supermarket Lighting Project
A European electrical contractor customized a T8 LED tube with G5 pins to retrofit existing T5 fluorescent fixtures in a supermarket chain project.
The project requirement was specific. The customer wanted to replace 54W T5 fluorescent tubes with 25W LED tubes while keeping the original G5 lamp sockets. Standard T8 LED tubes used G13 end caps and a 1512mm body length, which did not match the existing T5 fixture structure or the 1462mm lamp length.
VST Lighting developed a customized T8 LED tube using G5 pins instead of standard G13 pins. The tube length was adjusted to match the existing T5 fixture requirement, and high-brightness SMD LEDs were selected to reach about 2300lm per tube. The traditional ballast was removed during retrofit, so electrical compatibility and installation logic had to be confirmed before production.
In 2011, this type of LED tube replacement was not yet common. The key work was not only changing the end cap, but also matching the socket, length, brightness target, wiring method, and supermarket installation schedule. Tooling and first samples were completed in 30 days, followed by a first order of 1,525 pcs with a 20-day production lead time.
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