There is no doubt that having appropriate lighting in a factory setting can greatly enhance productivity, efficiency, and safety. The key to achieving success lies in selecting the right lighting design.
Unfortunately, many individuals struggle with this task as they lack the necessary knowledge on how to approach factory lighting. Questions often arise regarding the ideal brightness, power, type, and quality standards for industrial light fixtures.
But fret not! We are here to help. We will provide you with comprehensive information on factory lighting that is based on international standards and scientific research.
Factors to Consider When Selecting LED Lighting for Factories
1. Compliance with Industrial Lighting Standards
Choosing the right lighting for factories involves adhering to specific lighting standards set by organizations like the Occupational Safety and Health Administration (OSHO), the Illuminating Engineering Society (IES), and the American National Standards Institute (ANSI).
Understanding Lighting Units
To measure illumination, different units such as foot candles (fc), lumens per square feet (lm/sq.ft), and lux are used. These units help quantify how lighting is perceived. You can find more information about these units in our comprehensive guide available here.
OSHO Guidelines
OSHO, a government organization in the United States, provides lighting guidelines specifically for construction work in buildings and shipyards. Their guidelines specify the required illumination levels based on different areas within an industrial facility.
| Area of Application | Foot Candles (fc) / Lumens per Square Feet (lm/sq.ft) | Lux |
| Waste areas, dumps, loading, unloading, storage, excavation | 3 | 32 |
| Drilling, mining, underground tunnel work | 10 | 110 |
| Workshops, construction areas | 10 | 110 |
| Offices, halls, conference rooms | 30 | 325 |
OSHO standards for industrial lighting
IES/ANSI Guidelines
IES operates under ANSI and provides lighting standards for various industries including automotive, aerospace, general manufacturing, and workshops. Unlike OSHO’s guidelines that focus on specific areas within a facility, IES provides recommendations based on the type of work being performed. This allows for more flexibility in choosing appropriate illumination levels.
| Task / Work | Foot Candles (fc) / Lumens per Square Feet (lm/sq.ft) | Lux |
| Non-work related spaces, e.g., lobbies, hallways, etc. | 9-18 | 100-200 |
| Manufacturing of large workpieces | 18-46 | 200-500 |
| Manufacturing of medium-sized workpieces | 46-93 | 500-1000 |
| Manufacturing of complex workpieces | 93-186 | 1000-2000 |
IES standards for industrial lighting
Note
The values in the standard tables may seem lower than expected. However, it’s important to note that these values represent the perceived level of illumination by workers and not the actual illumination ratings of industrial lamps. Due to the significant ceiling heights in factories, even high-lumen flood lights may only provide a fraction of their output at ground level.
2. Considerations for Ceiling Height
Factories and industrial facilities often have high ceilings to accommodate large machinery and inventories. This poses a unique challenge when it comes to lighting design as different industries have varying ceiling heights. Taller ceilings require powerful fixtures to ensure sufficient illumination.
To provide a general estimate, consider the following:
| Ceiling Height (ft) | Lamp Output (Lumens) | Lamp Output (Lux) | Fixture Spacing (ft) |
| 10-20 | 10K – 20K | 107k – 215k | 10-20 |
| 20-30 | 22K – 35K | 236k – 387k | 15-25 |
| 30-40 | 35K – 47K | 387k – 506k | 19-29 |
| 40 and beyond | 47K + | 506k + | 30-40 |
Brightness and fixture spacing for large-scale industries
Consider Ambient Temperature
Ceiling height can impact the lifespan of lighting fixtures. With hotter air rising and colder air settling, temperature differences become more significant in taller ceilings. In some cases, the temperature surrounding light fixtures can reach up to 122°F (50°C). Experts recommend using weatherproof lighting with Ingress Protection (IP) ratings of 44 or higher to withstand extreme heat and humidity.
IP65 lighting fixtures are particularly suitable for such conditions as they require minimal maintenance while offering protection against harsh environments.
3. Lighting Requirements
Determining the appropriate amount of lighting for a factory depends on the nature of work and the size of the area. It is important to adhere to safety standards to ensure productivity and safety.
A good rule of thumb is that the height of the ceiling determines the spacing between fixtures both vertically (columns) and horizontally (rows). Additionally, it is recommended to have an even number of fixtures to avoid creating unnecessary shadows.
When the ceiling height exceeds 25 ft, it is advisable to place fixtures closer together. Refer to table 3 for more detailed information on fixture spacing and lumen ratings.
Factory Lighting Recommendations
Let’s consider a workshop that is 80 ft long and 50 ft wide, with a ceiling height of 20 ft. In this case, it would be ideal to install three lamps with a lumen rating of 22,000, placed at least 20 ft apart vertically. Another row should be added on the side, also spaced at 20 ft apart using the same type of lamp. This arrangement in a 3X2 pattern will provide sufficient lighting for productive work.
4. Types of Lighting Fixtures
Over the years, various lighting technologies have been used in factories. Traditionally, metal halides, halogens, and fluorescent bulbs were commonly used by factory owners. However, in recent times, LED lights have become dominant in the market due to their superior performance. Here are some popular types of fixtures commonly used in industrial settings.
High Bay Lamps
High bay fixtures are well-suited for tall ceilings typically ranging from 25 ft to 40 ft in height. They consume higher wattage and consequently produce greater illumination. High bay lights can be further categorized into two subtypes: UFO high bays and high linear bays.
UFO high bays have a unique fixture design resembling an alien saucer ship, which allows for wider beam angle light distribution.
Linear high bay lights are rectangular fixtures that provide even distribution of light. They can be either attached to the ceilings or suspended using chains.
Low Bay Lamps
Low bay fixtures are suitable for ceiling heights ranging from 15 to 25 ft. They offer uniform and precise light distribution at moderate heights. For better lighting, low bay lights can also be suspended using chains.
In addition to these general types, LED factory lights come in various sizes, power capacities, colors, temperatures, and CRI values.
5. Color Temperatures and CRI
In the realm of LED lighting, the Color Rendering Index (CRI) plays a crucial role in ensuring accurate color representation. For optimal factory lighting, a CRI score ranging from 75 to 85 is generally considered reasonable. However, if the nature of the work demands intricate color accuracy, opting for a higher CRI may come at a higher cost.
When it comes to choosing the right color temperaturefor factories and warehouses, most prefer cooler options within the range of 4000K to 6000K. This choice not only maintains a bright environment but also keeps individuals more alert and attentive to their tasks.
By considering these factors and selecting appropriate color temperatures and CRI scores, LED lighting can greatly enhance productivity and create an optimal working environment for employees.
How to Optimize Your Energy Savings with the Right Lighting?
Are you aware that lighting accounts for over 10% of your total energy expenses? The good news is that you can lower this cost by making a few smart choices. Here are some strategies to consider.
Take Advantage of Energy Rebate Programs
The US government offers incentives to factory owners who choose to install energy-efficient lighting, IT, and HVAC systems. In most cases, these incentives come in the form of cash rebates. By taking advantage of these programs, not only will you save money, but you will also have a sustainable long-term solution for your energy requirements. It’s truly a win-win situation. Currently, there are around 3000 utility companies that offer rebate programs.
Switch to LED High Bay Lights
LEDs are known for their high energy efficiency and cost-effective lighting solutions for various industries. They are easy to install and have a longer lifespan compared to halogens, halides, and fluorescent lights.
Embrace Natural Light
By incorporating large windows into your space, you can harness natural daylight throughout the day. This can significantly reduce your reliance on artificial lighting and subsequently lower your electricity bills.
Professional Guide to Installing and Upgrading LED Light Fixtures in a Factory
When it comes to installing lighting fixtures in a factory, the process is similar to any other location, but with the main difference being the size and quantity of fixtures needed. For small to medium-sized factories, it may even be possible for you to handle the installation on your own. Here is a step-by-step guide on how to install LED light fixtures in your factory:
Step 1: Gather the Necessary Supplies
Before starting the installation process, make sure you have all the required tools and equipment. This includes an industry-grade ladder, wire cutter, wire stripper, drill machine, and new high or low bay LED light fixtures. To ensure safety, always remember to turn off the main power supply before proceeding.
Step 2: Retrofitting (if applicable)
If you are retrofitting existing lighting fixtures in your factory, you will first need to remove the old fixtures. This involves removing the entire frame, starter, ballast (driver), and tube light if using older lighting technology. Once removed, you will be left with only the AC supply line which typically consists of three wires – active (brown or red), neutral (blue or black), and ground (green or yellow).
Step 3: Setting up the Bracket
Using a drill machine, securely attach the bracket by drilling it into either a wooden or steel base. The bracket should have a central screw that needs to be properly fastened. Once attached, proceed to mount the lamp frame onto the brackets and connect all necessary wires.
Step 4: Proper Wiring Connection
It is recommended to connect each of the three wires from both the lighting fixture and main power supply in a similar order for best practice. This means connecting red to red, black to black, and green to green. However, it’s important to note that even if you accidentally connect the active and neutral wires oppositely, LED lights are not affected.
Step 5: Ensuring Secure Connection
To ensure a secure and stable connection, utilize heat shrinks and wire connectors. These will help protect the wiring from any potential damage and ensure a reliable connection. After completing the connection, switch on the power to test the functionality of your newly installed LED lights.
By following these step-by-step instructions, you can confidently install or upgrade LED light fixtures in your factory. Remember to prioritize safety and consult with a professional if needed.
Advantages of LED Lighting for Factory Use
LED lighting fixtures offer numerous benefits that make them highly sought after in modern lighting design for factories.
Cost Efficiency
When considering the cost of any lighting appliance, it can be divided into three parts: initial investment, maintenance, and operational costs. While the initial cost of LED lights may be higher, it is worth noting that the long-term savings outweigh this initial investment.
LED lamps have an impressive lifespan of up to 50,000 hours and consume 40% less energy compared to older technologies. In contrast, a typical fluorescent light only lasts around 15,000 hours before needing replacement.
Versatility
LED technology provides a wide range of options in terms of colors and temperatures. Additionally, there are dimmable lights available that allow users to adjust the brightness according to their needs. Furthermore, advanced LED options include intelligent features such as motion detectors for added convenience and energy efficiency.
Minimal Maintenance
Unlike older fluorescent lighting, which often fuses prematurely or starts flickering, LEDs are highly durable and require minimal maintenance. Fluorescent lights would often require changing starters or replacing the entire tube. Additionally, traditional lighting options are not weatherproof and are susceptible to external damage. LEDs, on the other hand, are known for their longevity and lighting controls, eliminating the need for frequent replacements.
Furthermore, LEDs start up instantly without any warm-up time required as opposed to metal halides and fluorescent lamps.
Final Thoughts
In conclusion, after reading this comprehensive guide, you should now have a solid foundation for setting up efficient lighting in your factory, workshop, or warehouse. It is crucial to always keep in mind the importance of adhering to international lighting and safety standards.
Furthermore, we have provided you with valuable insights on how to reduce your electricity expenses without exerting much effort. By implementing these strategies, not only will you enhance your profitability but also create additional avenues for expanding your business.
Recolux Lighting Is A One-Stop Shop For All Your Factory Lighting
When it comes to achieving success with your lighting designs, settling for subpar luminaires simply won’t cut it. That’s why at Recolux Lighting, we pride ourselves on manufacturing premium quality lighting products in our state-of-the-art facility. Our team of industry-leading experts ensures that every product we produce meets the highest international standards and delivers top-notch quality right to your doorstep.
With a wide range of products available in our extensive catalog, including industrial, high bay, tri-proof, recessed, and spot LED lights, you have the flexibility to choose the perfect lighting solution for your needs. We understand that every project is unique, which is why we offer customized products to ensure that you get the most value for your money.
We believe in providing exceptional customer service and support throughout your journey with us. Our dedicated team of customer representatives is available 24/7 to assist you in making informed decisions and guide you through the entire process. Additionally, we offer a FREE evaluation of your project, allowing us to provide tailored recommendations and solutions.
Don’t wait any longer to experience the superior quality and service that Recolux Lighting has to offer. Get your quote NOW by contacting us through our website.
