Warehouse factory lighting solutions
How to choose the best lighting for your food facility
Choosing Efficient Warehouse Lighting Standard

Choosing Efficient Warehouse Lighting Standard Choosing Efficient Warehouse Lighting Standard

Low Bay Lighting Pros Cheap – these fixtures have are extremely cheap and been around forever. Replaceable Bulbs – in the rare case one of the LED tubes goes out, it’s easy to plug and play a new bulb.

Fast Upgrade – you can upgrade your current  fixtures easily with compatible LED tube lights.

DLC is a testing criteria for product performance and energy efficiency. There is two versions of DLC listings, Standard and Premium – premium being a much more strict standard. Many utility companies will provide rebates for using DLC listed lighting through their programs. If not for the rebates, we highly recommend getting DLC listed due to the extra tests lights have to go through. All Modern Place commercial grade fixtures come with DLC listings.

Low bay fixtures are meant for ceiling lower than 20 feet high. Typically these types of lights will go into smaller warehouses, shops, and lower ceiling stores. Many of the fixtures in circulation now are shop fixtures that just have fluorescent tube lights inside of them – we recommend replacing these with LED tubes instead which can be plugged right into the current setup for instant savings. This helps you save money on all new fixtures – this could save a large parking garage tons of money with a lot of the benefits.

Warehouses with high ceilings demand a specific lighting system in order to make sure the space is sufficiently bright to work in.

Light levels will be affected by the reflectance of surfaces within the facility, such as the walls, ceiling, floor, racks, pallets and containers. A black or dark colored wall or ceiling will not be as reflective as a white wall. For example, a space with two brown walls and two white walls may require six luminaires to provide the light levels required. The same space with four white walls will require only four luminaires. Keep in mind that shiny metal racks will reflect light while brown-colored boxes and other containers will absorb light.

Additionally, the cost of installing these luminaries is modest and the lighting quality is quite adequate.

The best way to determine the required horizontal and vertical illumination levels is to consider the average to minimum ratios. The horizontal average to minimum ratio for a rack area should not exceed 3:1. If the average light level in an aisle is 20 footcandles (fc), the minimum horizontal levels should be 6.7 fc or greater. The vertical average to minimum ratio for this same area should not exceed 10:1. This means that if the average footcandle level is 15, the minimum vertical footcandle level should never be less than 1.5 fc.

Several solutions are available to light a warehouse both properly and efficiently. A system that is well adapted to the space will serve to improve work habits and the well-being of employees while reducing maintenance fees and the cost of luminaires.

Finally, a LED lighting system significantly lowers heat output. Therefore, it is not necessary to air-condition a warehouse to counteract the heat produced by the lighting fixtures as LED lighting minimizes the cost of air conditioning. We call this “the cross-effect of lighting conversion” and it is an essential feature in the computation of cost savings. To learn more about cross-effects of lighting conversion, read Cross-Effect of Lighting Conversion.

Reduce maintenance costs Refresh the operational efficiency of a given space Increase work productivity Improve workers’ safety as well as their working conditions Respect the environment

High Bay UFO Lighting Pros Extremely Efficient – up to 170 lumens per watt Low Profile – rounds and easy to fit onto any ceiling Perfect For Outdoor Use – IP65 rated for all weather conditions and dusty environments.

Multiple Beam Angles – choose from more directional or less directional light. Cost Effective – lots of bang for the buck.

High Bay Linear Lighting Cons Few Choices In Beam Angles – the design itself makes this fixture have less directional light options.  Not As Efficient As UFO LED Lights – again, the design of the fixtures just isn’t as ideal for baseline performance.

Hard To Install – these take a bit longer to install but not by much.

High Bay Linear Lighting Pros High Efficiency – Up to 140 lumens per watt. Linear Light Distribution – perfect for high racks and not so open walkways. Rated For Outdoor Use – IP65 is fairly standard on these lights.

Cost Effective – almost as cost effective as UFO’s.  Anti-Glare – Many linear fixtures come with anti-glare capabilities. 

Fluorescent systems may be wired with multiple switching so that the luminaires within a certain area can be turned on and off as needed. This capability increases the system’s flexibility and allows the facility to take advantage of skylights and daylight harvesting to reduce operating costs.

Lighting uniformity within a warehouse space is essential. Forklift drivers and others must be able to look up and down the stacks of product without constantly having to adjust their eyes. The human eye functions more comfortably and efficiently when the luminance within the field of vision is fairly uniform.

Providing an element of uplight will help create a more uniform environment. Most glass luminaires will provide 15 to 20 percent uplight, which illuminates the ceiling and eliminates the cavern effect that can occur when a ceiling is dark. With a white or light colored ceiling, uplight will bounce off the ceiling to create a more uniformly illuminated environment.

It should be noted, however, that the initial purchase of a LED lighting system is a costlier investment than the simple purchase of traditional established lighting. When considering an overhaul of your warehouse lighting, you may also examine fluorescent lighting options.

See how we modernize our warehouse, read our Success Story STANDARD Warehouse

Low Bay Lighting Cons Usually Indoor Only – usually don’t have high IP ratings and meant to be used indoors Bulky – larger fixtures that don’t put out nearly as much light.  Lower Efficiency – even with tube replacements, using an existing ballast can result in much lower performance.

 

Controls   Lamps may burn constantly in areas that are continually in use. However, in peripheral aisles that are used only part of the time, warehouse operating costs can be reduced by turning HID lamps to lower levels when a space is unoccupied—or turning the fixtures off completely. A bi-level switching system may be installed to reduce the input wattage by 50 percent for metal halide lamps, or 35 or 50 percent for high-pressure sodium lamps.

How To Choose Warehouse Lighting June 2, 2017 – Posted in: Commercial Lighting

A poorly illuminated warehouse is an environment ripe for errors. Most warehouse facilities have a variety of functions performed within their walls—from picking operations and packaging to shipping and receiving, light assembly and even office work. These multiple tasks make lighting design a challenge because more than one task may be performed within the same area, requiring different light levels.

New luminaire and lamp technology has also made fluorescent systems better suited to warehouse environments. The new systems provide the illumination levels needed in facilities with higher ceilings and they use less energy than a metal halide system. For example, one 400-watt metal halide high bay fixture may be substituted with six 32-watt fluorescent fixtures for a total wattage of 192 vs. 400 (not including ballast losses).

But, in applications where employees are doing light assembly work or boxing product, color identification may be essential. Color rendering is the ability of the light source to represent the true colors in an object. The closer the color rendering index (CRI) is to 100, the more natural product colors will appear. The CRI of metal halide lamps is 65, with HPS lamps at 20. The CRI for fluorescent lamps is 80.

In many warehouses, lighting control components are often difficult to reach or may be too far to access. Motion sensors serve to coordinate the diffusion of light based on occupancy in various areas of the warehouse. In spaces where there is no activity, there is no need to keep lights on at all times; using motion sensors, warehouse owners can keep their energy costs down.

If efficiency is the primary concern, a high-pressure sodium (HPS) system is the most efficient light source available, providing the most lumens per watt. HPS lamps have a longer life than standard metal halide systems, which translates into lower maintenance costs.

Contrast and the size of objects involved in a task will also influence the light levels required. Tasks are easier to see when the contrast between an object and its background is greatest. For example, black lettering on a white label will have a higher level of contrast than dark blue lettering on a medium blue or medium gray background. Higher illuminance will help compensate for poor contrast and smaller objects.

Fluorescent systems also offer the advantage of “instant on.” All HID systems have a warm up time. During a power surge or outage, for example, a standard metal halide luminaire will require 10 to 15 minutes to cool down, plus an additional five to seven minutes to heat up. Fluorescent systems, on the other hand, will re-light immediately.

There are a few types of fixtures to choose from when it comes to high ceilings and large areas. Some are better fits for lower ceilings while others are designed for higher ceilings. Different designs also differ in the lumens per watt they provide so if you’re going to run a tight ship, you’ll have fewer options.

This, or a comparable mark such as ETL is the most important of them all. UL is a safety standard that certifies a product as safe to use. cUL is the Canadian equivalent of the same standard. Some projects may require UL explicitly and will not accept ETL standard products – although the testing is the same.

Whether the application is a new facility or a lighting retrofit, the question often arises as to what type of lighting system is best—a high intensity discharge (HID) system or fluorescent.

Great Brands Philips Lumileds (USA) Epistar (Taiwan) Cree (South Korean) Osram (Germany) Samsung (South Korea) Good Options Nichia (Japan) San’an (China) Ones To Avoid Generic Brands “White Label” Brands (they could be good, but don’t risk it)

Fluorescent systems operate cooler than HID luminaires. The higher the wattage lamps, the more heat an HID system will produce, which could lead to higher HVAC costs. If a facility’s air conditioning costs are unusually high and the lighting system uses high wattage lamps, the system may be retrofit with fluorescent luminaires or lower wattage HID lamps to reduce the operating costs.

Another thing to take into consideration is the LED chip brand used in your lighting. You should pay attention to this as choosing a vendor that has a “no name” brand might leave you with a lot of dead spots or dead fixtures. Often the best brands come with a small premium but it’s well worth the money.

High Bay UFO Lighting Cons They look weird I guess. Honestly, this style of light is taking over and everybody we’ve spoken to loves them – if you have a con for UFO lights, please email us. 

Luminaire placement will affect lighting uniformity. Warehouse managers typically try to get the most use of the space they have within their facilities. For example, if the ceiling height is 30 feet, products in the racks or on pallets may be stacked to within a foot of the ceiling. Mounting the luminaires in the middle of the aisles instead of directly above the racks or pallets will minimize shadows and will help assure maximum lighting uniformity.

If glare is a potential problem, consider using enclosed HID luminaires or a fluorescent system with a bottom lens. Installing luminaires with an element of uplight will also help reduce glare.

Many high ceiling lighting solutions offer additional features that are perfect for warehouse installations such as preventing loss of light due to the accumulation of dust, protecting luminaries against damage and facilitating their maintenance. Read about Luminaire Dirt Depreciation.

LED fixtures have become the buzz tool in the lighting industry; they are very well suited to warehouse lighting. LED highbays offer top performance as well as exceptional quality and versatility. They utilize 60% less energy than traditional fluorescent and HID lighting systems. Moreover, they are designed to reduce your energy consumption costs while providing your warehouse space with regular, contemporary lighting.

Posted in Lighting Aplication Recommandations, Our Online Journal. Last updated January 16, 2018.

Many warehouse owners and managers tend to prefer the white light provided by metal halide or fluorescent systems. Even though the measured footcandles may be nearly the same as for an HPS system, employees believe they can see better under a metal halide system because the environment appears brighter.

The age of the workers is another consideration when determining the light levels needed. As workers grow older, they require more light to compensate for degraded vision and the decreased size of the pupil. Attaining retinal illuminance for older workers equal to that of younger workers requires greater luminance on the task. (See Figure 2).

Lighting fixtures should be placed above the tallest rack or pallet for the best lighting distribution—which may make the case for using a low profile luminaire. Low profile luminaires may also be better suited to environments where forklifts are used to move merchandise so the forklift masts do not strike and break the luminaires.

If the warehouse receives a fair stream of natural light in some areas, for instance, it might be appropriate to reduce the intensity of your lighting system in those particular zones, thus significantly minimizing your energy costs.

These lights are perfect for creating an even light distribution, such as having these in between your warehouse racks to light up the walkways. If you walk into your local home depot, you will see the fluorescent version of this style of light. If you have high stacked goods, these might be a better choice for you as they come fairly close in terms of specs & performance to the UFO lights with a more linear distribution of light.  Typically these fixtures will be easy to install and connect together to form a single line of light. As with any commercial purchase, we recommend making sure you buy fixtures with a 5 year warranty.

When purchasing lighting for a new warehouse or hangar, we see many customers confused by all the options available on the market. In this post we’ll be listing the top pro’s and con’s of each type of warehouse light and going into the best options for each application. We’ve seen several people make terrible decisions based on either misinformation or investing into older technology.

A luminaire’s distribution pattern will contribute to a system’s uniformity. Fluorescent fixtures or HID luminaires with an asymetric (long and narrow) pattern are best for aisleways, whereas luminaires with a symmetric pattern are more applicable for open storage and shipping areas. In open areas where multiple tasks are performed, the ambient lighting may need to be supplemented with additional fixtures. For example, in an open storage space where light assembly is performed, supplemental fluorescent luminaires may be installed directly above the task to boost the light levels.

Summary   Warehouse managers, owners and designers have a variety of options when selecting the lighting system for a warehouse environment. But, no matter what type of system they choose, lighting uniformity is essential. A uniformly illuminated environment will not on promote worker safety but will improve performance. An efficiently illuminated facility will also impact the bottom-line.

Following are a number of solutions that will simplify the lighting choices for your warehouse.

Benefits of LED lighting include, among others, a longer life span. Ceiling height and the considerable number of fixtures in this type of space result in significant maintenance costs. Changing a simple light bulb often involves an elaborate process, such as the use of a forklift that can be quite costly in both time and dollars spent. LED maintenance and energy consumption are modest, two factors that represent major advantages in large spaces with high ceilings.

The above recommendations refer to the work plane. In warehouses, this is likely the vertical stack surface, and at times, the horizontal at document reading height. Adequate levels of vertical illumination are essential to read the labels on cartons, read signs within the facility (including exit signs), and to drive a forklift.

The installation of a luminous flux adjustor can also be a convenient lighting option for your warehouse.

Good lighting is essential in a warehouse to promote worker visibility, safety and performance. An efficiently illuminated facility will also reduce operating costs, which will impact the bottom-line.

These lights are very low profile, come in a variety of beam angles and the most efficient option to choose. UFO lights are just that, they look like small extraterrestrial objects that pack a massive punch. They come in a variety of mounting options overall very versatile. These lights can be used in stadiums, hangars, and high ceiling area. They are typically rated at 50,000 hours and should come with a 5 year warranty. We ourselves offer a full replacement warranty on this style of lighting . UFO lights also range up to 170 lumens per watt, although the price tag of those models doesn’t make them a smart investment at this time. The best balance of price and performance is around 130-140 lumens per watt.

The light levels and visibility required within a warehouse will depend upon a number of factors, including the tasks performed, the age of the workers and the type of space—whether it is an open space or has racks. The more active the area—such as a loading dock or staging area—the higher the light level requirements. Illumination levels will also be affected by the size of the items that are being handled. For example, an active area with small items (and small labels on containers) will require 20 to 50 footcandles on average. An active area with large items will require only 10 to 20 footcandles. An inactive area, such as a cold storage facility, will require only 5 to 10 footcandles.

These fixtures contain several T5HO tubes as well as a reflector that will angle the light flux toward the work space to ensure optimal visibility.

The down side of fluorescent systems is that they are heat sensitive. A fluorescent system may not be suitable for a warehouse in Texas that has no air conditioning during the summer.

However, many warehouse owners and managers are reluctant to use HPS systems because of the lamps’ yellowish color. In warehouse applications where storage, shipping and receiving are the main functions, color may not be an issue.

There is several types of certifications that you should be looking for when purchasing lights, some more important than others. Here is a short breakdown of each of the certification. Some of these certifications are absolutely required for commercial building in the US or Canada.

First off, you might as well say goodbye to metal halide or fluorescent lighting if your upgrading your fixtures completely. In this day and age, you’re just throwing away money if you’re investing in outdated technology, especially with how cheap LED based options are. This is especially true when talking about wholesale ordering of lights as the prices just keep getting better and LED’s keep becoming more and more efficient.

Warehouses and industrial buildings exhibit unique characteristics: few windows, high ceilings, elevated shelving, and large floor surfaces. All these factors require a very specific lighting system that adapts and conforms to the following needs:

Pulse start metal halide lamps are the most efficient metal halide lamps on the market. They not only provide the light levels needed, but they offer more light over the life of the lamp. A pulse start lamp will produce 110 lumens per watt (LPW) compared to 80 LPW provided by a standard metal halide lamp. Pulse start metal halide lamps also warm up faster to full brightness and have quicker restrike times. Although pulse start lamps cost more initially than conventional metal halide lamps, warehouse owners and managers benefit from lower installation, operating and maintenance costs (See Figure 1).

Our LED luminaires for high ceilings are designed for 18- to 60-inch mounting heights and will supply up to 95% of lumens for up to 60,000 hours. They are well suited to high ceilings (varying from 10 to 60 feet) and will ensure superlative quality, high performance lighting. They provide constant brightness with both direct and indirect lighting.

Warehouse facilities can also benefit from the use of T5HO fluorescent luminaires instead of LED luminaires.

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