Industrial Site Lighting and Industrial Manufacturing Site Lighting: Introduction

Industrial moisture-proof LED light

Industrial Site Lighting Overview

Industrial Site Lighting is divided into industrial manufacturing site lighting in the narrow sense and industrial site lighting in the broad sense.

Industrial manufacturing site lighting refers specifically to lighting for specific industrial production environments, product manufacturing, and industrial equipment operation sites. These lighting fixtures are designed to improve productivity, reduce work errors, and protect employee health and safety. Concentrated in Manufacturing Lines, Assembly Lines, Laboratory Areas, Maintenance Areas, Storage Areas, and other related work areas.

Broadly speaking, industrial site lighting refers to lighting fixtures designed for industrial environments such as factories, manufacturing plants, warehouses, and construction sites. These lighting fixtures are often characterized by high light output, long life, durability, and resistance to harsh environments.

Industrial site light is more demanding than the average commercial space. The lighting required must also be compatible with these areas. Industrial site light equipment should be rugged and impact resistant. Some Industrial sites may require waterproof or moisture resistant lights in hazardous areas.

Characteristics of Industrial Site Lighting

Industrial site lighting fixtures are designed to meet the light needs of industrial environments and lamps, they usually have the following characteristics:

1. High-intensity lighting:

Industrial site lighting requirements (e.g., 6000K color temperature, high luminous flux, no strobe, etc.) are usually higher than in general lighting environments, industrial site lighting must ensure optimal visibility of workers and machinery operations, Provides bright, uniform lighting to cover extensive areas to ensure that production proceeds normally.

2. Durability and robustness:

Industrial field luminaires usually have high water and dust resistance ratings (IP rating) and protection ratings (IK rating).

These luminaires are required to withstand the harsh conditions of industrial environments such as high temperatures, dust, humidity, vibration and corrosion. This requires industrial field luminaires to be constructed with materials such as metal and high-strength plastics.

3. Energy efficiency and cost control:

The number of lighting fixtures in industrial settings is often large and complex. In today's high-productivity environments, manufacturing In today's high-productivity environments, manufacturing facilities never rest, requiring 24/7 lighting operations. The high energy consumption costs have always been a pain point for industrial lighting. The high energy consumption costs have always been a pain point for industrial lighting. Therefore, how to save on electricity bills and energy expenses is one of the key considerations when selecting industrial lighting fixtures.

4. Safety and Compliance:

Outdated lighting technologies (e.g., metal halide, fluorescent, high-pressure sodium, high-intensity discharge lamps), may not be compliant with local environmental and safety regulations, and it is important to consider LED lighting conversions or retrofits.

The selection and use of fixtures at industrial sites must strictly follow local electrical safety standards and codes, such as CE, UL, CSA, and other certifications, to ensure that they do not pose any hazards to workers.

Types of Industrial Site Lighting Fixtures

The role of LED lighting as an efficient light source in industrial sites is becoming increasingly prominent, and many manufacturing plants are looking at replacing traditional factory lighting fixtures with LED fixtures to save on energy costs and maintenance, enhance the visual environment, and increase color recognition. It's important to implement a comprehensive LED lighting retrofit, and here are a few industrial site lighting fixtures you should have.

LED High Bay Light fixtures

Designed for areas with ceiling heights of 20 feet or more, LED High Bay Lights are used to illuminate flat surfaces both vertically and horizontally and can be used with a variety of reflectors. These LED industrial site fixtures illuminate large, spacious spaces such as warehouses, manufacturing plants and assembly areas. In addition to the older round UFO LED high bay fixtures, LED linear high bay fixtures are now preferred because of their wider and more uniform illumination, which outperforms traditional fixtures in many important aspects (e.g., average life span, Correlated Color Temperature (CCT), instantaneous on/off, dimming ability, directionality, efficiency, heat emissions, etc.).

Low Bay Light Fixtures

LED low bay fixtures are typically suitable for industrial sites with less than 20-foot ceilings and mounting heights, and provide a full spectrum of crisp, clear white light. Not only do low bay LED fixtures provide higher light levels than traditional metal halide and fluorescent fixtures, they also provide better light uniformity and coverage.

Vapor Tight Light Fixtures

Vapor Tight Light Fixtures are designed to withstand the harsh conditions of wet locations and areas where dust, dirt or steam can affect the performance of common industrial site lighting. These fixtures are tightly sealed to prevent the ingress of water and steam and are constructed of corrosion-resistant materials such as polycarbonate or stainless steel, with protection ratings of IP66, IK10 and higher. Ideal for industrial sites such as certain food processing plants, refrigerated warehouses, and outdoor docks.

LED Ceiling Light Fixtures

LED Ceiling Light Fixtures are available in three standard sizes: 2FT, 4ft, 5ft. Traditional industrial site fixtures typically use T12 / T8 tube fluorescents, halogens, etc., while LED solutions utilize LED T8 tube fixtures or LED batten light fixtures. deciding on the best solution will depend on your facility's current operating conditions. LED recessed light fixtures can be surface mounted, pendant mounted, or chain hung. The choice of how to mount a recessed fixture depends on the fit of the ceiling and the desired light performance.

Which LED industrial site light fixtures to use depends on the environment and type of work, but of course there are many other industrial site light fixtures, such as

LED UV Resistant Lights: These lights are typically used in industrial sites where sensitive materials need to be protected from UV exposure, such as precision instrument manufacturing, chemical storage, and these fixtures are effective in blocking UV rays up to 400nm.

LED High Temperature Lights: These LED lights are designed to work in high temperature environments, they are able to work properly at temperatures of 45 degrees, 55 degrees or even higher for high temperature industrial environments such as steel manufacturing, glass manufacturing and more.

LED Explosion-proof Lights: Explosion-proof LED luminaires are specially designed for industrial sites where there is a risk of explosion, such as petrochemicals, coal mines and so on. These lights are made of special materials and designs that can prevent sparks in flammable and explosive environments, thus ensuring the safety of the workplace.

LED Waterproof Light Fixtures: Suitable for industrial sites in humid or watery environments, such as food processing plants, sewage treatment plants and so on. These lights have high waterproof and dustproof rating, such as IP65, IP66, which can work normally and provide continuous lighting in industrial sites with high humidity or direct contact with water.

Industrial Site Lighting Standards

In America, industrial lighting footcandle requirements are set by a variety of standards and guidelines, including those of the Occupational Safety and Health Administration (OSHA), the American National Standards Institute (ANSI), and the Illuminating Engineering Society (IES). These requirements vary depending on the specific work environment and task. Below are some common lighting requirements.

OSHA (Occupational Safety and Health Administration) Industrial Lighting Standard

OSHA's general industry standard (29 CFR 1910.37) states that employers must ensure that workplaces are adequately lit for the safety and health of employees. Below are some reference standards:

  • General work areas (construction site lighting, warehouse lighting, sidewalk and hallway lighting): 5 footcandles minimum.
  • Mechanical and electrical equipment areas: 10 footcandles minimum.
  • Offices and other areas requiring delicate work (first aid station lighting, machine shop bench lighting): 30 footcandles minimum.

ANSI (American National Standards Institute) Industrial Lighting Standards

ANSI/IES RP-7-01 “Recommended Practices for Lighting in Industrial Environments” states:

  • Light industry (e.g., assembly line lighting and test line lighting): 50 footcandles.
  • Medium industry (e.g., general manufacturing lighting and assembly lighting): 30 footcandles.
  • Heavy industry (e.g., metalworking lighting and heavy manufacturing lighting): 20 footcandles.

IES (Illuminating Engineering Society) Industrial Lighting Standards

IES provides detailed lighting design guidelines and recommended footcandle levels for specific tasks and environments. recommendations in the IES manual include:

  • General manufacturing lighting: 50 footcandles.
  • Fine assembly and inspection lighting: 100 footcandles.
  • Roughing and storage lighting: 20 footcandles.
  • Electronic assembly lighting: 200 footcandles.

SUMMARY

Specific requirements for industrial lighting vary depending on the type of work and environment. Ensuring that industrial lighting meets these standards is critical to increasing productivity and ensuring employee safety. Below are some reference values:

  • General work areas (construction site lighting, loading dock lighting, warehouse lighting, sidewalk and corridor lighting): 5-20 footcandles (OSHA and IES).
  • Mechanical fabrication and electrical equipment area lighting: 10-30 footcandles (OSHA and ANSI).
  • Office, detailed work area, and precision manufacturing lighting: 30-200 footcandles (OSHA, ANSI, and IES).

Industrial Site Lighting Application Scenarios and Characteristics

Industrial lighting fixtures play a key role in a variety of industrial sites such as production lines, factories, tunnels and warehouses. It involves improving visibility and safety and increasing productivity in demanding industrial environments through specialized industrial LED batten Light fixtures. Unlike residential or commercial lighting, industrial lighting must meet stringent requirements to withstand harsh conditions and ensure optimal performance. Here are some common industrial site lighting scenarios:

Construction Site Lighting

Flexibility and Rapid Deployment: Industrial LED batten Light fixtures are designed to be flexible and easy to install, with a consistent and efficient lighting output that ensures worker and equipment visibility at night or in low-light conditions, effectively reducing the risk of accidents. Industrial LED batten Light fixtures are particularly useful for construction projects with high flexibility and can be quickly deployed in different work areas.

Tunnel and Mine Lighting

Explosion-proof and waterproof with durability: Designed for extreme environments, Industrial LED batten Light fixtures are explosion-proof, waterproof and corrosion-resistant, making them suitable for wet and dusty underground workspaces. They are also equipped with emergency lighting so workers can still evacuate safely in the event of a power outage.

Warehouse and Manufacturing Facility Lighting

Precision Lighting and Energy Savings: Warehouses and manufacturing facilities require well-designed lighting systems to promote safety, quality control and worker productivity. From ceiling lights for production areas and warehouses, LED lights for conveyor belts and warehouse high bay LED lights, to industrial wall sconces for perimeter security, COMLED illuminates where it's needed most. Our industrial LED batten light fixtures also help to reduce energy consumption and minimize lighting maintenance time.

Shipyard and railroad yard lighting

Weather Resistant & High Output: In outdoor locations such as shipyards and rail yards, Industrial LED batten Light fixtures provide the reliable performance of weather resistant and high output lighting to facilitate outdoor operations and inspections. These fixtures are designed to take into account the special requirements of the environment, such as wind, rain and salt spray resistance.

Task and Maintenance Lighting

Protection and Impact Resistance: COMLED offers high protection industrial LED batten light fixtures for task and maintenance areas, providing optimal lighting for worker productivity and safety in industrial applications. These impact resistant lights provide protection in challenging environments where collisions can occur. Our task and maintenance fixtures are ideal for service, maintenance, repair, inspection and cleaning operations in both indoor and outdoor environments, including wet or hazardous locations.

Food Manufacturing & Beverage Production Lighting

Clean & Safe: Hazmat-certified industrial LED batten light fixtures provide clean, reliable lighting that meets stringent health and safety standards in food production and milling operations.

Wood, Pulp and Paper Manufacturing Lighting

Clarity & Durability: Industrial LED batten Light fixtures provide high CRI (Color Rendering Index) illumination that enhances visual clarity and ensures workplace safety, while providing durability and maintenance-free features.

Automotive & Aerospace Lighting

Ruggedness and Smart Controls: COMLED's fixtures offer high temperature resistance, long life, and smart controls compatible with building management systems for high-intensity production environments in the automotive and aerospace sectors.

Wastewater and Water Treatment Plant Lighting

Glare-free and efficient: Industrial LED batten Light fixtures provide glare-free lighting for wastewater treatment plants, enhancing visibility and safety while supporting the efficient operation of the facility, contributing to public health and environmental protection.

COMLED's Industrial LED batten Light fixtures further enhance these applications, ensuring that industrial sites continue to operate efficiently and properly even in harsh environments such as washdowns, dust, high temperatures, and corrosive environments, thus protecting investments and maximizing profitability.

Benefits of Industrial Site Lighting Fixtures

Industrial lighting fixtures are made, taking into consideration the stringent needs of general industrial site environments, much specifically to the liking of production lines, factories, tunnels, and warehouses. These LED fixtures offer numerous advantages that help improve safety, efficiency and productivity in industrial environments.

1. Durability and longevity

Rugged Construction: Industrial lighting fixtures are designed to withstand adverse conditions, such as extreme temperatures, humidity, dust, and vibration. They are normally fabricated with materials that assure long-term performance with reduced maintenance costs, featuring aluminum, stainless steel, or otherwise heavy-duty plastics able to withstand all types of abuse.

Longer Lifespan: COMLED Industrial LED Batten Light Fixtures outlast the conventional light fittings by far. The lifetime of LEDs is as much as 50,000 hours or even more, which would require less replacement and, in turn, less maintenance on a lower scale.

2. Enhanced Safety and Compliance

Improved Visibility: COMLED Industrial LED Batten Light Fixtures feature bright, glare-free illumination and reduced shadows, excellent for improving visibility of an area. Much can be said about the importance of improving these things within an industrial environment; for instance, in reducing accidents and ensuring worker safety.

Compliance in Safety Standards: Most industrial lighting fixtures are manufactured with compliance in achieving strict safety requirements so that they can obtain certifications like CE, SAA, C-tick, LVD, EMC, IEC, LM80, RoHS, and ETL applicable to safe usage in critical industries—nearly relevant to hazardous conditions.

3.Flexibility and customization

COMLED Industrial LED Batten Light Fixtures: Adjustable Lighting, Flexible Installation. COMLED industrial batten light fittings have inductive dimming functions, which can allow one to customize the dimming control to specific needs. Flexible customization of lamps and lanterns opening time, brightness, color temperature, length, and emergency lighting function, and so on. Other possible installation methods include ceiling surface mounting, hanging, and wall mounting, among others. That is the adjustment of lighting distribution, which, consequently, enhances task visibility and, ultimately, productivity in general.

Various Options: The COMLED Industrial LED Batten Light Fixtures can be provided in several types and configurations, which include high-bay and low-bay, moisture- and waterproof lighting. This allows industries to have the most appropriate lighting fixture used in every application, resulting in the best performance and efficiency.

4. Energy Efficiency and Environmental Protection

Energy efficiency: COMLED light fixtures with industrial LED strips use one-fifth to one-tenth of the energy that traditional incandescent or fluorescent lamps require, this will save a great deal of your money spent on electricity bills. Meanwhile, LEDs generate much less heat than traditional light sources, there will be less need for extra cooling systems to make a much more comfortable and safe working environment.

Environmental benefits: LED lighting fixtures do not contain mercury and other harmful substances, are recyclable, and have low energy consumption that can reduce greenhouse gas emissions. With respect to this, long life accompanied by high energy efficiency reduces the frequency of replacement at industrial sites and promotes long-term environmental sustainability.

 

Frequently Asked Questions:

What are LED industrial site lights and manufacturing lighting?

LED industrial site lights and manufacturing lighting are site specific lighting solutions for industrial and manufacturing environments. They are designed to give high levels of light, durability and energy efficiency. They are used in factories, production lines, warehouses and other industrial areas where reliable and powerful lighting is critical for safe and efficient operation. They are built to withstand harsh conditions such as dust, moisture and temperature fluctuations.

What are the benefits of LED industrial lighting compared to traditional lighting?

LED industrial lighting has many advantages over traditional lighting options like incandescent, fluorescent and high-intensity discharge (HID) lamps. First, LEDs are super energy efficient, using way less power to produce the same or better light. This means big savings on your energy bill over time. Second, LEDs have a much longer life, up to 50,000 hours or more, so you replace and maintain less often. Third, LED fixtures produce better light quality with better colour rendering, so you see more and are safer in industrial environments. Unlike traditional lighting, LEDs don’t contain mercury and are more environmentally friendly. They also produce less heat, so you have a cooler working environment and less load on your cooling systems. Overall, switching to LED lighting can improve your operational efficiency, safety and sustainability in industrial applications.

How long do LED industrial lighting fixtures last?

LED industrial lighting fixtures last from 50,000 to 100,000 hours depending on the quality of the LEDs and the conditions they are used in. That’s 5 to 10 years of continuous operation, much longer than traditional lighting technologies like incandescent or fluorescent bulbs. This means less replacement and maintenance and lower overall costs.

Are there any incentives for switching to LED lighting?

Yes. Many governments and utility companies offer rebates and tax incentives to encourage businesses to go energy efficient. Plus LED lighting can save you money on your energy bills due to its higher efficiency and longer life than traditional lighting. Add to that reduced maintenance costs and switching to LED lighting is a no brainer for many industrial and commercial businesses.

How does the durability of LED industrial lighting compare to other types of lighting?

LED industrial lighting fixtures are known for their ruggedness and durability, perfect for harsh industrial environments. Unlike traditional bulbs which can break due to their fragile components, LEDs are solid-state lights, they have no filaments or glass enclosures that can shatter. This design makes LEDs shock, vibration and impact resistant. They also work in a wide range of temperatures, from extreme cold to high heat, without compromising performance. They are also better suited for areas with high switching cycles as they don’t have reduced lifespan due to frequent on-off switching. These features ensure LED fixtures perform consistently and reliably in the toughest industrial conditions, reducing downtime and maintenance costs.

Can LED fixtures run 24/7 in a warehouse?

Yes, LED fixtures are designed to run continuously in a warehouse environment. LEDs are energy efficient and have a long life so are perfect for applications where lights need to be on for long periods. They also generate less heat than traditional lighting so reduce the load on the HVAC and make the working environment more comfortable. Plus LEDs maintain their brightness over time so you get consistent light for 24/7 operation.

What to consider when choosing LED industrial lighting?

When choosing LED industrial lighting, consider the following to get the best performance and efficiency. First, think about the lighting requirements of the application, such as the required brightness (measured in lumens), colour temperature and beam angle. The IP rating of the fixture, which indicates its resistance to dust and moisture, is also important especially in harsh or outdoor environments. Energy efficiency is reflected in the fixture’s efficacy (lumens per watt) so make sure you get cost savings. The lifespan and warranty of the fixture is also important for long term reliability and reduced maintenance costs. Make sure to check for industry standards and certifications to ensure safety and quality. Finally, consider the ease of installation and compatibility with existing electrical systems to minimize disruption and extra costs.

Are there tunnel specific requirements?

Yes, tunnel LED lighting has specific requirements for safety and driver visibility. These are high luminous efficacy to give enough light, uniform light distribution to avoid dark spots and glare, high colour rendering index (CRI) to show colours and improve visibility. Tunnel lighting must also be designed to withstand the harsh environment found in tunnels such as humidity, dust and exhaust fumes. Emergency lighting and backup power systems are also critical to keep the light on during power outages.

What is the ideal brightness level for the manufacturing plants?

In manufacturing plants, the proper level of lighting greatly depends on the nature of the work performed. In general, lighting at a level occurring within 500 and 1,000 lux is normally recommended for most manufacturing tasks, ensuring effective brightness that guarantees the safety and productivity of the workers. Precision work will require up to 1,500 lux lighting. Your optimal lighting environment should minimize shadows and glare while providing adequate illumination for all areas; use ambient, task, accent lighting—each specific for its own place.