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LED Factory Lights

LED Lighting for Factories - high heat and explosion proof solutions plus high powered and high voltage LED High Bays and flood lights. Convert your factory over to LED quickly and easily.

Lighting in a factory plays a huge role on safety, security, and output. Converting to LED factory lighting fixtures away from high-pressure sodium or metal halide lights has proven to improve all three of those areas, all while reducing energy consumption up to 75%.

Common Factory Lighting Problems

 

Insufficient lighting to meet the needs of the space
  • Too much light which causes glare
  • Improper contrast
  • Flicker
  • Poor distribution of light

So, how much light is enough for factory settings?

There are no predetermined foot candle standards for industrial settings. Sufficient light for different environments largely depends on:

  • The general size of the workspace
  • The type of task being executed and its demands for accuracy and speed
  • The variety of surfaces in the space. Are they reflective, do they absorb light?
  • The length of time employees spend in the space

 

Advantages of Good LED Lighting for Factories

An ILO manual called The Improving Working Conditions and Productivity in the Garment Industry (pg 45) shows improved lighting can lead to a 10% increase in productivity. It can also result in a 30% reduction in common errors. Improving lighting has many other benefits including:

 

  • Employees can identify hazards in the workplace. They will also be able to know if their working environments are unsafe. Changes can be made to ensure that no harm comes to those at risk
  • With good lighting, employees can read warnings, work instructions, product details, and safety data.
  • There is a reduction in factory accidents because workers are more comfortable and efficient
  • Better accuracy in workmanship
  • Less spoilage of products
  • An increase in labor production
  • Better working and living conditions
  • A reduction in the adverse health effects of eye strain
  • Enhanced supervision by officers and managers
  • Increased workplace satisfaction and contentment of workers
  • Improved safety and security

Factory Photometric with LED High Bays

Why are photometrics important? They allow you to see your area and how it would look under LED Lighting taking the risk out of buying. We can run different options with our lights. This provides you with proper information and guidance. We're here to save you money with LED. But it's as important to get the lighting right.

 

LED Lighting for Factories Lowers Operational Costs

Steel Factory Image

Factory owners today are in a state of constant pressure to reduce operational costs. This is because high operational costs have a direct impact on the final prices of goods. One of the easiest ways to cut overhead costs is by using efficient factory lighting.

A 2015 U.S. Department of Energy report showed that the commercial sector used 37% of all lighting electricity. It was the leading consumer of lighting electricity in the U.S. This sector has long operating hours and needs many lighting fixtures.

Many factories today are switching from HPS lamps, metal halides, and fluorescents to LEDs. Light emitting diodes or LEDs have without a doubt, revolutionized the lighting industry. They are gaining ground due to their advantages, the biggest being cost savings.

While LEDs have been in electronics for years, high power LEDs are what gave the technology fame. They're versatile lighting systems and are durable enough for infrastructure and manufacturing lighting.

Some DLC qualified LEDs use almost 75% less energy than other types of lighting sources. They also last 25 times longer than other light bulbs. Estimates show the widespread adoption of LEDs will save over 348TWh of electricity by 2027. Going by today's electricity costs, this is about $30 billion in savings!

A diode is an electrical component or device with a cathode and anode. Electricity flows through these two electrodes in one direction. The diodes are semi-conductive materials such as selenium or silicon. These solid-state materials conduct electrical current only in specific voltages, light intensities, or current levels. Once an electric current passes through the semi-conductive materials, the LED emits light.

6 Benefits of LED Lighting for Factories

LED Diodes Image

 

1. An Extreme Long Life Expectancy

The useful life of LEDs ranges between 50,000 hours and 100,000 hours. So, what makes them last so long? We’ll answer this question by asking another question, "why do all the other bulbs burn out so quick?”

All other bulbs borrow the working mechanism from Thomas Edison's incandescent bulb. Fluorescents don't have filaments but electrodes that emit electrons into a gas inside the tube. The electrodes evaporate with time, burning out the fluorescent tube.

LEDs have a very long lifespan because of the way they are designed. Why? They never burn out. In fact, they have nothing to burn. They have no filaments and no oxidation or evaporation of components. They suffer no metal fatigue. While other bulbs have high levels of fragility, LEDs are tough and have no glass components to break.

Thanks to electro-luminescence, LEDs need little electricity to power them. They produce negligible levels of infrared energy.

So, if they never burn out, why do they have a life expectancy rating? Well, LEDs may not burn out, but their light output will decrease over the lifespan. But, they will still continue to produce 70% of their light until they reach the end of their lifespans.

2. Extremely Energy-Efficient

When compared to other bulbs, LED's are energy efficient. This makes them perfect for factories and industrial spaces. In a LED, electricity passes through the semi-conductive material, sparking up the diodes.

A heat sink will absorb and release the small amount of heat generated in a process known as thermal management. Thanks to this process, LEDs do not release heat into the environment. Flourescents and HIDs convert a whopping 80% of the energy they draw into heat. This means they only convert 20% into light.

LEDs also disperse their light directionally over a 180-degree angle and not in 360 degrees like HID and fluorescent lighting. This eliminates the need for reflectors to redirect the light. LED lights for factories produce higher-quality light. And at half the average energy consumption of older lighting fixtures.

Savings with LED

3. Perfect for Factories that Operate for 24 Hours

 

Some factories run for 24 hours, which is why it makes so much financial sense to invest in LED technology. LED lights lower a factory’s energy consumption and decrease the maintenance costs related to lighting. This helps businesses save a lot of money on electricity.

LED lights need a higher initial investment than other lighting systems. Yet, this will be offset with their low running costs. The longevity and reliability ensure that there’s minimal downtime. Which makes them perfect for hectic production environments.

There is a massive move towards LED lighting for factories. Companies are realizing the many benefits they provide when compared to older lights.

LED Factory Lighting Image

4. Improved brighter environment and factory safety

 

Industrial environments, such as factories, have a lot of dangerous machines and processes. Improving the visibility with higher quality LED lights enable employees to avoid accidents. Chances are greater with sub optimal HPS or Metal Halide lamps. We can EASILY replace 400W, 1000W and even 2000W HID, all while saving $'s.

 

5. Increased productivity

HPS and MH lights buzz, flicker, and have less-than-optimal color temperatures and quantities. This can slow down production, reducing daily output. Being able to speed up efficiency pays for itself. Not including the direct cost saving benefits that industrial LED factory lighting offers.

6. LED Lighting Solutions of Hot and Cold Environments

 

Some factories suffer from heat produced from furnaces and other processes. We can offer an indoor highbay solution that is designed for environments up to 190F. Cold Environment? We got you covered there too! The same fixture is rated for -85F. We replace 250, 400 and 1000W HID and if you need more, ask us. We custom build solutions.

4 Considerations when Choosing LEDs for Factories

While too little lighting in a factory can be hazardous, too much of it can cause glare and up operational costs. A lighting pro has to take into consideration the uses of the factory space. Also the lighting requirements before settling on any factory lighting fixtures.

There is no “one size fits all” light fixture for industrial locations. The Illuminating Engineering Society (IES) recommends lighting designers always do a photometric analysis before recommending any solutions. They should, for example, take an inventory of the available spaces, the occupants, and the functions of the spaces.

The following are the most important considerations for factory lighting.

1. Lux Levels

Lux is the standard unit of measurement for light level intensity. 1 lux of light is equal to 1 lumen per square meter. It tells us how well a surface is illuminated. A lux measures light intensity as perceived by the human eye. The lux levels for direct sunlight range between 10.8 (twilight) to 120,000 (direct sunlight at noon).

There are different lux levels recommendations for various industrial applications. A lux meter ensures illumination levels are perfect for a task, a space, and the workers.

Below is a table highlighting the recommended lux levels for different industrial settings

 

Application Recommended Lux
Fine inspection 5,000
Detailed assembly 2,000
General assembly 1,000
Work area 150
Warehouse 100

 

 

2. The Working Conditions

The light fixtures in factories may be exposed to excessive levels of dust, oil, or moisture. These fixtures need to withstand extreme conditions that's the norm in industrial settings. They should also have adequate protection against vibration and impact. Vibrations may cause damage from the heavy machinery used in most factories. When in extreme conditions, fluorescents can shatter. This can expose the products, the equipment, and the employees to risk.

Continuous vibrations can degrade lighting solutions that use fine filaments and delicate components. LED lights for factories do not have filaments or glass enclosures. They are resistant to impact and vibrations in industrial settings.

The lights should also have temperature protection features to function in high and low temp environments. The extreme ambient temperatures that are usually found in factories make LEDs more suitable. LED lights can work well in refrigerated warehouses with temperatures of up to -40°C.

 

3. The Color Rendering Index

Most LED lights for factories have a high color rendering index of 80-90. This means that the workers in a factory actually see the true colors of objects. A high CRI is important in inspection areas. Especially areas where products are inspected before they are released to the market. It is also important in paint manufacturing plants where accurate color discrimination is vital.

Traditional lighting systems, like metal halide and fluorescents, have a low CRI that ranges 50 to 65. When they are in factories, there is a considerable deviation in color.

LED Color Rendering Index (CRI)

Lower Costs with LED Image

4. Maintenance Costs

The maintenance costs of the lights is a very important consideration. If you use HID solutions like high pressure sodium lamps, you will need to replace them yearly on average. This is because traditional lighting solutions have a high rate of lumen depreciation. They lose most of their light output by the time they get to 40% of their rated lives.

The LED lights for factories sold by MyLEDLightingGuide have a rated life of 100,000 hours. They last for more than 10 years if they operate 24/7, or close to 30 years if on for 8 hours a day. Using these lights will save a lot of money. You won't be replacing lamps and spending money on the labor for installation.

Reducing factory lighting costs is then practical and sustainable with LEDs for factories. With energy savings up to 75%, you can reduce a tremendous amount of energy consumption. Also , LED offers longer lifespans and reduced maintenance costs.

Rebates are available at time of purchase.

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