Creating good industrial lighting is very important and involves proper design criteria while taking into consideration the type of work performed. High quality lighting is important in the manufacturing process especially for safety and task lighting. Industrial Lighting covers a wide spectrum of areas from lighting huge factory floors to small tool areas to very specific specialized tasks and everything in between. LED lighting is the perfect choice for industrial lighting.
The Importance of Industrial Lighting: Detail
The ability to see detail used to be addressed by wattage, throw enough light at the situation and it should solve the issues. Unfortunately this approach rarely worked because all it did was create glare and made the lighting situation worse and created a poor work environment.
Medical science has shown a direct correlation between good health and good lighting. Better lighting contributes positivity to task performance by improving speed, lowering failure rate and a higher safety rate.
LED lighting is an important addition to industrial lighting because of the type of light LEDs produce. LED’s produce light very much like the sun which produces light with a high amount of blue in its spectrum. This type of light improves visual acuity. Traditionally fluorescents and metal halides produce light with a high amount of yellow which is not very good for visual acuity. The spectral charts below show the drastically better quality of light LEDs produce.
The installation of LED lights in an industrial facility will greatly improve visual acuity for complex assembly reducing eye strain and creating a better working environment.
Industrial Lighting Fixtures for Corrosive, High Moisture Areas and Heavy Vibration
Since LED are diodes, they don’t use a filament to produce light which makes them a much better fit for areas with heavy vibrations such as a heavy stamping plants, roadway, bridges and tunnels. Fluorescents and HID lamps with filaments tend to break sooner under heavy vibrations making replacing them costly and time consuming.
The picture to the right is a Lusio® 4M washdown series which is a sealed, water tight housing LED Luminaire. It is perfect for high moisture areas, food processing, cold storage and some corrosive applications.
Industrial Lighting in Extreme Temperature Conditions
For most traditional industrial lighting, temperature wreaks havoc on the fixtures creating longer warm up times and shorter life spans. LEDs work exceptionally well in cold storage applications producing little or no heat adding to the energy savings by creating less of a load on the refrigeration systems. To the right is a picture of an ice cream storage facility using D3’s Thermalway high bay outfitted with occupancy sensors for on demand usage. The Thermalways used were 100 watts and replaced a 460 metal halide. LEDs are excellent choices for cold storage applications.
The picture below is of a D3 Thermalway LED luminaire, they have a powered coated metal frame for added durability and corrosion resistance and large heat sinks for high efficiency.
Improved maintenance costs
By implementing a LED lighting system in your industrial facility it will greatly reduce your maintenance costs associated with lighting. LED’s contain no lamps or ballasts which need to be replaced. Many of today’s industrial LEDs have an average life span of up to 200,000 hours. The average yearly cost to main 20, 400 watt metal halides is roughly $1,200 and could be considerably more if you are outsourcing.
Superior Energy Savings
Review of a real life example of upgrading 400w Metal Halides with Lusio 4M’s.
If you look at the wattage reduction by upgrading to LEDs over multiple fixtures and time, the savings can be tremendous. Let’s look at a basic example by taking 20 of the 400w metal halides at 457 watts in a factory setting that operates 16 hours a day, six days a week and replace them with 17 of the Lusio Essentials Bay 4M’s
Current fixtures below
The above analysis shows the kWh savings per year to be 21,864 with a total operational savings of $44,073 over a ten year period based on an initial investment of $15,231. Imagine what the savings can be if you have 100, 400w metal halides.
Control Systems for Industrial Lighting
Lighting Controls are a great way to add additional energy savings to an already very energy efficient LEDs. LEDs are solid state devices making them inherently controllable and an excellent addition for an industrial lighting project.
Bi or Multi Level Dimming
Multi-level dimming is a great way to further reduce energy cost and still maintain expectable light levels. How multi-level dimming works. An area with multi-level dimming would be at reduced light level, such as 20 or 30 percent when no one is in the area. Multi-level dimming sensors in an area detect the presence of fork lift or person and adjust the light levels back to 100%. If the sensors detect no movement in the area after a certain amount of time the light level are dropped back down.
Occupancy sensors work very much like Multi-Level dimming except they turn the lights off after a certain programmed time period and instantaneously bring them back on as soon as a person or forklift enters the area.