Understanding the right lighting that spaces like factories and other facilities need is very crucial for the owners as well as the electricians who carry out the process.
The process gets further complicated by the high risk of accidents and other hazards that exists in these spaces.
Both the things complicate each other as poor lighting increases the risk factor multi-folds.
The two organizations Illuminations Engineers Society and American National Standards Institute have designed the factory lighting standards that have been readily adopted by the OSHA.
This means that there exist penalties for the factories not following the standards.
What methodology was used for the standards?
The standards of the lighting and luminance levels in factory settings weren’t set by any novice but only experts.
This becomes very important as not every factory has the same settings that make their lighting demands varying too as per their settings.
To satisfy these conditions, the IES/ANSI standards were devised with enough room to accommodate all kinds of lighting needs.
These standards are the essential standards that every lighting system must meet. For instance, the lighting needs of the office area and assembly area in a factory would be different.
General Guidelines: ANSI/IES-RP-7-1991
The metric of measurement for light levels is called lux (one lumen per square meter) and the lux meter follows the same metric.
While the ANSI/IES guidelines set the essential conditions for lighting systems, they also are enough flexible to contain all individual demands.
Like, the ANSI/IES standards recommend around 10-20 foot candles light levels in the areas like lobbies or dining areas where visual clarity is not a crucial need.
At the same time, they recommend 20-50 foot candles for areas where visual clarity and high color contrast is important for the tasks.
Similarly, the workstations like electronic assemblies need extremely precise visual clarity and the apt light levels for such areas have been recommended to be 200-500 foot candles.
Factory Lighting Types
Any ideal factory lighting system when combined with suitable indoor support equipment becomes able to provide the perfect illumination for the target areas that involves bright, evenly distributed, and glare-free lighting coming from simple fittings.
1. General Lighting
The common lighting methods used in workshops and factories involve the affixture of a pre-defined number of bulbs at a certain height to light up the target working space evenly and uniformly.
The height is further increased in the bigger machinery workshops because they receive the movement of big machines like cranes frequently.
It would be wise to put some additional lighting in these bigger spaces to light up the vertical plane better.
2. Task Lighting
Precision is required in many of the tasks that are carried out in certain spaces that generate the need for bright and specialized local lighting.
The lights can be customized for this purpose by attaching the fixtures with benches or machines via adjustable fittings or even affixing them on movable floor bases. Using deep reflectors reduces glare too.
The factories also include portable hand lamps fixed at various spots with wall plugs and trailing leads to facilitate enough lighting for emergency ad maintenance needs.
These hand lamps use low voltage lights or 50 or lesser Volts due to the thicker filaments of these lights that impart them with higher strength and reduced vulnerability to electric shocks; overall, they are better for safety reasons.
All such low voltage light systems can be supplied with power through a different low voltage distribution system that can be installed in the factory or through a mini transformer that gives the power supply to each light system separately.
Local lighting is crucial and mustn’t be installed aloof. It does better with general lighting that provides for the dark gaps. These dark gaps between the local lights stress out the eyes as they take more time to adjust their vision to the light conditions.
3. Emergency Lighting
This type of lighting holds crucial importance for so many places that exist in almost every factory and workspace. We have given a list of such places below that need LED emergency lighting.
These lights are the auxiliary ones that must come from a different source than the primary power supply like petrol-drive mini generators or batteries mostly.
Even if they have to be powered from the primary power supply only, their connection shouldn’t be done with the primary lighting circuit ever.
- Internal pilot lighting facilitates safe emergency evacuation needs when the primary lighting circuit goes down.
- External pilot lighting gives further evacuation benefits by providing efficient shades that give sheltering effect.
- Lights must be there for medical care centers, control posts, etc.
- Gauges and dials provide for the usual watch needs while installed in plants during air raids that call for precautionary measures including factories turning off lights.
LED High Bay Lights for Factory Lighting
What makes photometric crucial? These facilitate a digital representation of lighting settings that can be viewed beforehand and modified as per the needs to be assured about the purchase.
You can even test these plans with different lightings. The aim is to make the buyer properly informed.
This will save you money too. Just choose the ideal light!
Lighting levels for factories
Light level intensities are measured with the unit called Lux. 1 lux of light equals I lumen per square meter.
It represents the illumination level of the particular surface. Lux represents the light intensity that is visible to the human eye.
Sunlight has the following lux levels- 10.8 during twilight to 120000 during the noontime.
Different industrial settings require different lux levels. This is checked with the help of a lux meter that calculates ideal illumination levels for space, affected bodies, and activities.
The table below gives the adequate lux levels suitable for various industrial settings.
Why LED Lighting Supply Manufacturing And Factory Are Lights A Better Option?
1. Higher Efficiency or Lumens per Watt
The true efficiency of any light source is denoted by its luminosity efficiency.
This is a measure of the lumens produced by the light for every watt of power it consumes and this value can be used for the comparison of LED and other bulbs.
LEDs have far higher efficiency than every other light. The efficiency ratings are even higher for high-quality LEDs.
Our LED fixtures have 130-180 lumen/watt ratings. Let us give you the most efficient LEDs.
How do long term savings make up for the initial cost?
The cost of higher efficiency LEDs is higher than the low-efficiency bulbs. Similarly, the savings that they generate is much higher than the initial investment they require.
We recommend you choose higher efficiency LEDs for maximum savings with LED conversion.
2. Lumen brightness
LED Lighting Supply provides many versatile options that come with different styles (linear/UFO), voltage, optics, wattages, etc.
Our fixtures offer around 5000-100000 lumens each and are good for 15-40 ft high ceilings. We also offer multiple optic sets.
We aim to provide uniform, even, and high luminance for your settings.
How to determine the ideal light system?
This is very tough. We can help you with our lighting software that assesses your building layout.
Further, we understand your lighting demands. Finally, the software will give us the proper watts, lumens, fixture style, optics, etc. details related to your building lighting.
3. Adapts for different Voltages
Are you replacing high voltage fixtures like those with 277 or 480V? We have got you here with our high voltage light systems.
We provide the constant current drivers that are designed to handle a range of voltages like 277-480 Volts along with standard driver kits that handle 100-277 Volts.
We provide solutions for variable power phases too like single or 3-phase. Our sales engineers will get you through all this.
Options for 480V lights
Our high voltage fixtures can work for 480V installations in both single and 3-phases. Our sales engineers can help with the 277V installations and drivers too.
4. Options for high temperatures
Heating problems in certain settings can seriously damage the LED lights. Thus, you need LED fixtures that remain resistant to temperature fluctuations beyond 50 to 122F too.
We have two high-temperature Flood and High Bay lights ranges.
Options for high-temperature lights
Range 1: 70C or 158F
Range 2: 80C or 176F
Range 3: 90C or 194F
We do provide high-temperature resistant fixtures but we recommend you to never install any fixture in the direct path of gas or hot air sources.
The color of any light is denoted by the CRI or color rendering index. This helps us differentiate the color visibility of any object under the target light and sunlight.
The poor light color quality of HID lamps makes them unsuitable for various settings. The properly visible light color makes huge differences in factory settings.
The color contrast and clarity come out clearly.
We offer various LED Factory lights with CRIs between 70 and 85. You can request customized CRI lights with us too.
CRI of LEDs
CRI scores of over 70 are all good. If you want lights for special spaces where fine colors and detailing is crucial, go for 80-90 CRI.
Ways factories benefit from LED lighting
We discussed above in detail the unique qualities of LED lights. However, the list of their benefits is even longer.
By upgrading factory lighting with LEDs, you can boost productivity by up to 10% and reduce error risk by up to 30%. Several of the benefits include:
- The hazards in workplaces become easily identifiable. The workers will be able to judge the environmental risks better. This will allow dealing with the risks in time to make everyone safe.
- Proper lighting allows the workers to read the details like warnings, instructions, safety data, product description, etc.
- The risk of accidents gets reduced with a safer and comfortable environment for the workers.
- Workers perform better and precisely.
- Product spoilage risk gets reduced.
- The overall Labor output increases.
- Living and work conditions for the people present in the facility improve.
- Health effects like eye strain reduce as well as the other ones.
- Managers and officers can supervise better with every space visible clearly.
- Workers feel more satisfied with the workplace environment along with active.
- Security and safety of the workers increases