LED Lighting for Industrial Factories

What are LED Factory Lights?

Manufacturing environments require lighting solutions beyond standard commercial fixtures. Factory LED lights must withstand harsh conditions and deliver reliable, high-output illumination. With 15+ years serving industrial clients, we know that effective factory lighting needs robust construction, temperature resistance, and proper ratings for hazardous areas. Some facilities require LED high temperature lights or LED explosion proof lighting for hazardous zones. Our durable industrial LED lights for factories and manufacturing plants offer:

• High lumen output with up to 60% energy savings over metal halide, model dependent
• IK10 impact resistance for forklift and machinery areas
• IP65 waterproof rating for wash-down zones
• Operation up to 302 F ambient temperature, model dependent
• UL844 explosion-proof certification for hazardous locations when properly specified

The U.S. Department of Energy's industrial lighting studies show that LED technology can reduce energy use by 50-90% compared to traditional high-intensity discharge systems in manufacturing. DOE's comprehensive analysis of LED benefits in industrial settings highlights significant cost savings and improved lighting quality for manufacturing environments.

Types of LED Factory Lights for Manufacturing Plants Use

Factory lighting selection depends on your environment and operational needs. Most manufacturing facilities use one or more of these fixture types:

NFPA 70, the National Electrical Code, sets strict requirements for lighting in hazardous locations to prevent ignition of flammable gases, vapors, or dusts. The NEC's hazardous location classifications define installation and equipment standards for manufacturing environments where explosive atmospheres may exist.

What are the Benefits of Using LED Lights for Factories and Manufacturing Facilities?

• Dramatic Energy Reduction - Most industrial installations save 60-70% on electricity, model dependent. A 300-watt LED UFO can replace a 1000-watt metal halide with more usable light.
• Superior Light Output - Fixtures deliver up to 150 lumens per watt, creating brighter workspaces with less power. Workers report less eye strain and better accuracy on detailed tasks.
• Color Accuracy - Factory LEDs maintain CRI above 70, helping workers distinguish wire colors, read labels, and spot defects.
• Consistent Performance - Quality LEDs maintain 90% of initial output over their lifespan, unlike metal halides that dim over time.
• Maintenance-Free Operation - With 12 hours daily use, these fixtures can run over 10 years without bulb or ballast changes, reducing downtime and labor.
• Industrial-Grade Construction - Every fixture is quality tested before shipping. We offer 5-year warranties with USA-based support.
• Emergency Power Integration - Optional battery backup modules keep lights on during outages. Emergency systems work with 0-10V dimming controls for code compliance.
• Universal Voltage Compatibility - Auto-sensing drivers work with 100V-277V or 277V-480V systems. Install into existing infrastructure with no rewiring.
• Smart Motion Detection - Integrated or add-on sensors reduce energy waste. Lights dim to 10% output when unoccupied, then return to full brightness with motion.
• Forklift-Proof Durability - IK10 impact ratings help fixtures survive machinery impacts and falling objects. Reinforced housings protect components in tough environments.
• Flexible Installation - Choose from eyehooks, pendant mounts, trunnion brackets, or wire guards. All mounting systems support full fixture weight and enable quick installation.
• Maximum Light Output - Our highest-output models generate 90,000+ lumens, model dependent, for 40+ foot ceilings and large manufacturing spaces.
• Building Automation Ready - 0-10V dimming compatibility integrates with automation systems for zoning, scheduling, and daylight harvesting.

How Many Lumens Do You Need to Light a Factory?

Proper factory lighting depends on ceiling height and task needs. We typically recommend these lumen ranges by mounting height:

OSHA, ANSI, and IES Foot Candle Requirements for Factory Lighting

Meeting regulatory lighting standards protects workers and ensures compliance during inspections when properly specified. OSHA sets minimum requirements for factory environments:

ANSI and IES offer more detailed recommendations based on visual task requirements:

OSHA's workplace lighting standards emphasize that adequate illumination is essential for safe working conditions and accident prevention. OSHA's construction industry lighting requirements set minimum illumination levels for work areas, while the Illuminating Engineering Society provides recommended practices for industrial lighting design and implementation that go beyond basic safety requirements.

Safety and Performance Certifications

All our fixtures carry essential certifications, including DLC Premium for energy efficiency and rebate eligibility, and UL Listed and ETL Listed for electrical safety and performance, when properly specified. These certifications help qualify your project for utility rebates and tax incentives, subject to local utility programs. DLC Premium certification verifies high efficiency and maximum rebate eligibility.

The DesignLights Consortium sets performance standards for LED lighting products to ensure energy efficiency and rebate eligibility. DLC's Qualified Products List includes only fixtures meeting strict photometric and electrical criteria. Underwriters Laboratories provides safety testing through UL's LED lighting certification programs to ensure products meet national safety standards.

5-Year Warranty and Warranty Support

All our lights include at least a 5-year warranty, with USA-based support. Our team understands the importance of keeping your lighting operational and will work quickly to resolve any warranty issues.

Expert Industrial Lighting Support and Custom Solutions

Our product specialists have designed lighting solutions for thousands of manufacturing facilities across many industries. We provide complimentary custom lighting plans that calculate fixture placement, energy savings, and ROI for your facility, subject to site conditions. Our team understands industrial requirements, including hazardous location classifications, temperature needs, and OSHA compliance. Before you invest, let our experts analyze your current energy use and create precise savings calculations based on your local utility rates and schedule. We provide detailed photometric layouts to show how your facility will look after the upgrade.

Common Mistakes and How to Avoid Them

Most factory lighting failures result from not matching fixtures to the actual environment. These mistakes can create safety hazards and lead to early failures.

• Using standard LED fixtures in hazardous locations without proper UL844 certification violates OSHA requirements and creates explosion risks. Always check Class and Division ratings with your local authority before ordering.
• Installing fixtures rated for normal temperatures near furnaces or heat sources causes driver failures. High-temperature fixtures cost more upfront but prevent costly callbacks.
• Mounting UFO high bays with narrow beam angles can create dark spots. Wide beam angles are better for most factory ceilings.
• Connecting fixtures to the wrong voltage destroys drivers and voids warranties. Double-check nameplate voltage against your supply before energizing circuits.
• Skipping impact protection in forklift areas leads to fixture damage and potential injuries. Wire guards and IK10 ratings help prevent most impact damage.
• Installing fixtures without proper IP ratings in washdown areas allows moisture in, damaging electronics. Use IP65 minimum for wet or humid environments.
• Using inadequate mounting hardware for heavy fixtures creates hazards if fixtures fall. Calculate total weight, including mounting components, and verify structural support.
• Over-lighting wastes energy and creates glare. Run photometric calculations to determine actual fixture quantities needed.

LED Lighting for Industrial Factories Frequently Asked Questions

What are LED Factory Lights?

LED factory lights are industrial-grade fixtures built for manufacturing environments, featuring IK10 impact resistance, IP65 waterproof ratings, and operating temperatures up to 302°F ambient, model dependent. Options include UL844 explosion-proof fixtures for hazardous locations and high-temperature models for foundries and steel mills.

What are the benefits of using LED lights in a factory?

Factory LEDs deliver 60-70% monthly electricity savings depending on model, with output up to 150 lumens per watt and CRI ratings above 70 for accurate color distinction. Fixtures maintain 90% of initial output throughout their lifespan and include 5-year warranties with USA-based support.

How many lumens do I need to light a factory?

Lumen requirements depend on ceiling height: 15,000-22,500 lumens for 15-20 ft ceilings, 18,000-30,000 lumens for 20-30 ft, 40,800-45,000 lumens for 31-40 ft, and 72,000-96,000 lumens for 40+ ft ceilings.

What are the foot-candle requirements for factory lighting?

OSHA minimums range from 3 foot-candles for loading platforms to 30 foot-candles for offices and first-aid stations. ANSI and IES recommend 50-100 foot-candles for small-scale visual tasks with medium contrast and 100-200 foot-candles for very small-scale tasks with low contrast.

What certifications should factory LED lights have?

Factory fixtures should carry DLC Premium, UL Listed, and ETL Listed approvals for safety and rebate eligibility. Hazardous locations require UL844 certification for Class I, Division 1 and 2 environments.

Can LED factory lights handle high temperatures?

High-temperature LED fixtures are rated for ambient temperatures up to 392°F and feature specialized heat sinks and driver protection for foundries, steel mills, and hot manufacturing processes.

Are LED factory lights compatible with dimming and automation systems?

Factory LEDs integrate with building automation through 0-10V dimming compatibility for zoning, scheduling, and daylight harvesting. Motion sensors dim lights to 10% output when areas are unoccupied, then return to full brightness instantly when motion is detected.

What voltage do LED factory lights require?

Auto-sensing drivers work with 100V-277V or 277V-480V systems without modification, allowing direct installation into existing electrical infrastructure.

How durable are LED factory lights in industrial environments?

IK10 impact ratings protect fixtures from machinery impacts and falling objects, while IP65 waterproof ratings prevent moisture infiltration in washdown areas. Reinforced housings protect critical components in rugged environments.

What is the warranty on LED factory lights?

All fixtures include at least a 5-year warranty with USA-based support.