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Industrial Factory LED Lighting Solutions

LED Warehouse Lighting Will you save money with LED lighting for your factory? Will the lighting improve after you're done? These are all questions we hear every day. Here is some insight we gathered over the past 8 years that might help you make this decision regarding making the switch over to LED Factory Light sources.


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Will I save money with LED Lighting for my Factory?

The short answer is yes, LED lighting for factory applications will save you money. But how much really depends on the type of lighting system you currently have, the hours of operation and the cost of your electricity.  If you currently have Metal Halide or High Pressure Sodium, the savings are typically 65% or higher by converting over to LED factory lighting fixtures. If you have fluorescent tubes, like T8's, T10s or T12's, then you should see on average a 50-66% savings. And if you have high bays (which consume a lot of energy due to high lumen output), converting your factory to LED high bay lights could save you near 70% in energy consumption making it a great energy saving factory lighting solution.

150 LED Watts replacing 400 MH Watts
12 hrs/day 365 days/yr saving 1358 kw/year *
 
Cost per kw/h
Savings per year
.06
$81
.08
$109
.10
$136
.12
$163
.14
$190
.16
$217
.18
$244
.20
$272
* includes ballast draw

And this is only the start of savings, add reduced maintenance costs of replacing bulbs and ballasts or add smart controls like occupancy sensors and daylight harvesters and savings can go much higher.

Indoor Factory LED Lighting

High Bay LED Lighting


LED High Bays can replace Metal Halide High Bays up to 1500W and reduce your energy consumption by as much as 75%. These lights are perfect for gyms, warehouses, factories, auditoriums or any large area where traditional style high bays are installed. UL Listed and DLC Qualified with 5 year warranties.




Explosion Proof LED Lighting


Our explosion proof LED Lights are UL 844 certified for  Hazardous Areas and we have models that are Class 1 Div 1, Class 1 Div 2, Class 2 Div 1 , Class 2 Div 2 and Class 3. DLC Qualified for rebates, we can replace up to 400W Metal Halide with as much as 19,000+ lumens.




Commercial LED Tube Lights


Fluorescent troffers are typically found in suspended ceilings, and they typically contains 2 to 4 fluorescent tubes. Most tubes are either T8, T10 or T12. There are two distinct options that are available, replace the fixture with LED Panels or replace the tubes with LED Tubes. The tube option tends to be more economical, and with the creation of plug and play led tubes, converting over to LED is as simple as removing the old fluorescent tube and replacing it with the LED tube.


High Bay LED Retrofit Kits


LED High Bay Retrofit Bulbs are designed to replace Metal Halide and High Pressure Sodium in your existing High Bay fixture. This is nothing more than replacing your existing bulb and ballast and screwing in the retrofit bulb. Easily replace up to 400W Metal halide.


LED Retrofit Kits


LED Retrofit Kits are designed to replace Metal Halide and High Pressure Sodium in your existing fixture. This is nothing more than replacing your existing bulb and ballast with the LED Retrofit Kit Head and LED Driver. 11 kits are available to replace everything from 70W to 1500W HID, making them a good option for any LED HID retrofit conversion. Extremely efficient up to 165 lumens/watt and DLC Premium Qualified to maximize your rebates!


 
How long before I see my lighting system investment get paid off?
 
That all depends on five factors pertaining specifically to your factory LED lighting system as a whole. Hours of use, cost of electricity, what you convert to, rebate amounts and cost of the new fixtures. Of these three factors, 1, 2 and 3 are the most important. If your lights are only on 4 hours a day or one of the lucky ones who pay under .07 kw/h, then paybacks will typically be longer. However, if you are north of .10 kw/h and have high usage, then paybacks can be relatively short. If you choose a product that is only rated at 100 lumens/watt, then your paybacks will be longer. Select higher efficiency (above 125 lumens/watt) products and paybacks will drop because you need less LED watts. We are still surprised when customers call us and tell us they were quoted from a competitor that pay back would be 3 years or more, and when we do our calculations, we find it to be under 2 years and sometimes under 1 year. There are still those out there that are either charging too much for their product or not selecting the most efficient product available. The fourth factor, rebates, is not always available and certainly not the same across the USA. They are set by your local utility company. The good news is most of our product is rebate eligible, and we know how to work with the utility companies to get the maximum rebates available. Sometimes they are as high as 50% of the cost of the product and installation.  Lastly, the cost of the new equipment divided by the total savings will give you your payback period.

 
Will the light levels improve?
400W HPS              150W LED

Typically, in most cases, yes. Keep in mind, a brand new Metal Halide bulb is very bright. You will also notice on the package of the Metal Halide bulb it talks about initial lumens. The manufacturers who make these products have designed the product so that after the initial lumen brightness wears off (and it doesn't take long), that what is left is what you really need for a safe environment. If what you needed was the initial lumens, you would be replacing bulbs every 6 months. LED is directional light, so we place all the light where it is needed. With conventional MH lights, 30% of the light produced is lost in the fixture itself. There is just as much light going sideways as there is going down, and you need reflectors to gather that light and push it down. More than 1 bounce in the reflector and you can throw that light lumen away. With LED, there is no bouncing or need for reflectors. And more importantly, the quality of light is better with LED. We always say, you need less quantity when you have better quality lumen output. But how can you confirm this before you buy? Easy! We can do a photometric evaluation for you on your space. This will show you the light levels of our product in your environment before you purchase to keep you within your factory lighting requirements. And we can also sample lights so you can see before you purchase. That way there are no surprises.

Special needs? We have explosion proof and high temperature LED High Bays
 
Do you have explosion proof lights in your current facility? We can provide LED High Bays that are UL certified with Class 1 Div 1, Class 1 Div 2, Class 2 or Class 3 certifications. These lights can produce close to 20,000 lumens of maintenance free light for years, while keeping your factory safe and bright.

Have an area with high temperatures? We have a special LED High Bay that is designed to work in areas up to 90C or 190F. That's significantly better than the rating for almost all LED products on the market today. Click here to check out our high temperature LED High Bays.

How long do Commercial LEDs for factories last?
 
There are two numbers companies talk about, the life of the LEDs (L70) and the life of the product. L70 is a measurement of the LEDs where they reach a point of 70% of initial lumen output. We were at a trade show recently and one vendor was talking about their product lasting 200,000 hours. Turns out that was the L70 number. That is impressive. However, you also have to take in consideration the life of the LED of the product driver. They are typically less than the products L70. So we asked them how long their drivers were rated for. They said 50,000 hours. So then we asked if it was easy to swap out the drivers in their product. They said no, it wasn't even an option. So after 1/4 of the life of their LED's, you were going to have to buy a new LED product. So a general rule of thumb is to pay attention to the life of the product drivers, not the L70 of the LEDs, and ask if the drivers can be replaced. There should be no reason why you can't get 10-20 years life out of a LED product with maybe one driver replacement. 

 

Are there rebates available at time of purchase?

Yes, and no. Rebates are controlled by your local utility. So it varies. But this is what we know. For small screw in bulbs, make sure the product is Energy Star Rated. For larger fixtures, make sure the product is DesignLights Consortium Listed. Recently, DLC came out with a newer higher standard, DLC Premium. DLC Premium is a standard where the products are ultra high efficiency. And this matters to you for two reasons. First, the rebate amounts are higher than DLC Standard. And two, you will consume even less energy with a DLC Premium product than a DLC Standard product. We have many DLC Premium Products available to help maximize your savings, shorten your paybacks and help you qualify for the largest rebates available. Not only will you be eligible for higher rebates, but you will also realize the benefits of the energy efficient factory lighting which reduces a lot of electricity usage in factory facilities.


Will retrofitting my existing factory lights save me more money?

Yes, they will. Better yet, retrofitting will save you money in almost every aspect of your factory lighting LED upgrade. While a factory LED retrofit kit is no more efficient than an entirely new fixture, a factory lighting retrofit can save you money in the following ways:

1. Typically less expensive per fixture. For obvious reasons, a retrofit kit is cheaper than an entirely new fixture (typically). This factor alone can save you a lot of money in your initial investment in an LED factory lighting system.

2. Less costly to install. Installing entirely new fixtures takes more time. You've got to remove the existing fixture, dispose of it, then install the new one. And if you are paying someone to do this, it can get expensive. Whereas with retrofitting your existing factory lighting fixtures you simply replace the existing light source and keep the fixture. This is much quicker, produces less waste, and is a huge cost saving benefits and why we advocate for you to retrofit if you can. So by retrofitting, you still get your proper LED lights for factory setting without the costly investment of entirely new fixtures.


The only time we won't recommend a retrofit kit in your existing fixtures is if they are old, outdated, or simply outlived their life. But if you want help deciding and where to start, be sure to contact us by clicking here; there are commercial factory lighting experts waiting to answer all of your questions!


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