LED Binning: Guaranteeing Lighting Standards

LED binning is a quality control process that sorts LED chips by color temperature and brightness to ensure consistent lighting performance. This process directly impacts the uniformity and quality of commercial LED fixtures like high bay lights, area lights, and flood lights.

Safety Note: qualified electricians should perform LED lighting installation in accordance with local electrical codes and manufacturer specifications.

What is LED Binning?

When white LED chips are manufactured, they produce similar but not identical light output and color characteristics. Manufacturing variations mean each batch contains chips with slightly different properties.

To ensure consistent lighting performance, manufacturers test and sort these chips using specialized equipment. This sorting process is called binning – chips are literally placed into separate containers (bins) based on their test results.

The goal is simple: group similar chips together to minimize variations in light output and color within a single lighting product. Once binning is complete, the sorted chips are packaged and ready for use in LED high bay lights, LED shoebox lights, LED flood lights, and other commercial fixtures.

Binning Strategy: Quality vs. Cost

LED manufacturers face a key decision when developing their binning process:

• Larger bins (fewer categories): Less expensive, but allows more variation in light characteristics
• Smaller bins (more categories): Tighter consistency but higher costs, resulting in more expensive final products

The two most critical factors tested during LED binning are:

• Luminosity: Light output measured in lumens – relatively straightforward to test and categorize
• Color temperature: Light color characteristics – significantly more complex to evaluate

The Science Behind Color Binning

Color binning relies on research by David MacAdam, a color scientist who studied human color perception in the mid-20th century. MacAdam mapped color differences onto the CIE color space (established in 1931) to understand how people actually perceive color variations.

MacAdam’s research revealed that people group similar colors as “nearly identical.” When mapped on a color diagram, these groupings form ellipses – known as MacAdam ellipses or Standard Deviation Color Matching.

LED binning uses these ellipses placed around reference chromaticity points. The ellipses define areas on the color chart where all colors appear indistinguishable to the human eye. LEDs binned within these areas provide visually uniform light colors.

Color Temperature vs. Correlated Color Temperature

Understanding the difference between these terms is important for specifying LED lighting:

Color Temperature: Defined by comparing light to an idealized black body radiator heated to specific temperatures. As the temperature increases, the color becomes “cooler” (more blue). Lower temperatures produce “warmer” (more red/yellow) light.

Correlated Color Temperature (CCT): Since LED light sources don’t perfectly match the black body curve due to manufacturing processes and materials, their color is described as “correlated” to the nearest equivalent temperature on the black body curve.

Industry Standards and Applications

Because manufacturers developed their own binning systems, NEMA published SSL 3-2010 “High Power White LED Binning for General Illumination” to standardize minimum binning areas and ranges.

Choosing the Right Binning Level

Smaller binning isn’t always better. Tighter bins create extraordinary costs because unused LEDs from the same manufacturing batch become difficult to sell. The key is determining acceptable color variations for your specific project requirements.

Consider these factors:

• Application type (office, warehouse, retail, outdoor)
• Fixture spacing and mounting height
• Budget constraints
• Color consistency requirements

Expert Guidance for Your Project

Selecting appropriate binning specifications requires balancing performance requirements with project budgets. Talk to the lighting experts at LED Lighting Supply for guidance on binning requirements for your specific application.

Future Developments

Research continues to improve LED binning methods. The Technical University Darmstadt in Germany is developing “New Binning Strategy for White LEDs“ that connects LED binning more directly to visually acceptable chromaticity differences, potentially improving future consistency standards.

Disclaimer: LED product specifications and performance can vary by manufacturer. Always consult product datasheets and manufacturer guidelines for specific applications. Professional installation is recommended for all commercial lighting projects.