How to choose industrial lighting?

I’ve seen it time and time again—businesses installing the wrong lighting, only to deal with safety hazards, skyrocketing energy costs, and productivity dips. Poor lighting can lead to accidents, downtime, and expensive maintenance. But here’s the good news: with the right industrial lighting setup, we can enhance safety, cut costs, and boost efficiency. Let’s break it all down.

When choosing industrial lighting, I always focus on safety, efficiency, and durability. It’s all about getting the right balance of lumens, wattage, color temperature, and fixture resilience. LED lighting is my go-to—it’s energy-efficient, lasts long, and slashes maintenance costs. Smart controls? A game changer. They adjust lighting based on real-time needs, cutting operational expenses. If you want a well-lit, safe, and cost-effective workspace, picking the right fixtures and controls is key.

Let’s dive into the specifics so you can avoid common pitfalls and make the smartest choice for your business.

Common Challenges for Lighting in Industrial Environments

Lighting in industrial environments isn’t just about flipping a switch—it’s about safety, efficiency, and cost control. I’ve seen too many businesses struggle with outdated, inefficient lighting that wastes energy, creates safety hazards, and racks up unnecessary maintenance costs. Let’s break down the biggest lighting challenges and how to solve them once and for all.

Harsh Conditions

Factories, warehouses, and industrial facilities are tough places for lighting. Extreme temperatures, humidity, dust, and constant vibrations wreak havoc on fixtures. Add in chemicals, moisture, and airborne debris, and your lights won’t last long—unless you pick the right ones.

What’s the fix? Go for IP65/IP66-rated LED fixtures that can handle dust, water, and heavy-duty environments. If your facility deals with flammable materials, explosion-proof lighting is a must.

Sky-High Energy Bills

Old-school HID and fluorescent lights are energy hogs. They burn through electricity, driving up your costs and wasting energy you don’t need to use. Every extra watt is money out of your pocket.

Want a real fix? Switch to LED industrial lighting. You’ll cut energy use by up to 70% while getting better, brighter lighting. And if you add smart controls like motion sensors and dimmers, you’ll stop paying for light in empty spaces.

Safety Risks That You Can’t Ignore

Bad lighting in an industrial space is an accident waiting to happen. Dimly lit workstations? That’s how mistakes happen. Poor visibility in aisles? That’s a trip and fall lawsuit just waiting to hit your inbox.

The solution? Make sure every area has the right lux levels—at least 200–300 lux for general warehouse space and up to 1000 lux for detailed work. And don’t forget glare-free, flicker-free LED fixtures—because eye strain and fatigue are just as dangerous as bad lighting.

Maintenance Nightmares

Ever tried replacing a high bay light 30 feet up? It’s time-consuming, expensive, and a huge hassle. Traditional bulbs burn out fast, and if you’re constantly swapping them out, you’re throwing away money on labor and replacements.

How do you fix this? Invest in long-lasting LEDs that give you 50,000+ hours of life—that’s years of zero-maintenance lighting. No more shutting down operations just to change a few bulbs.

If you’re tired of high energy bills, safety risks, and constant maintenance headaches, it’s time to upgrade to LED lighting. You’ll get brighter, more reliable, and cost-effective lighting that actually works for your business.

What Are the Guidelines for Industrial Lighting?

Industrial lighting isn’t just about brightness—it’s about efficiency, safety, and compliance. If the lighting is too dim, you risk workplace accidents. If it’s too harsh, workers suffer from fatigue. Finding the right balance ensures productivity while keeping energy costs low. Below are the key guidelines for industrial lighting and how to implement them effectively.

Illuminance Levels

The right illuminance level depends on the type of work being done. General areas require moderate lighting, while detailed tasks need higher brightness for accuracy. Here’s a general breakdown:

• General warehouse and storage areas: 100–300 lux
• Assembly and packing areas: 300–500 lux
• Precision workstations and inspection areas: 500–1000 lux
• Loading docks and security zones: 100–200 lux

Proper lux levels ensure workers can see clearly, reducing errors and improving safety.

Color Temperature

Color temperature, measured in Kelvin (K), affects visibility and alertness. The ideal color temperature for industrial environments typically falls within these ranges:

• 3000K (warm white) for break rooms and offices
• 4000K (neutral white) for general work areas
• 5000K–6500K (cool white) for warehouses, production areas, and detailed tasks

Cooler temperatures improve focus and visibility, making them ideal for manufacturing and inspection areas.

Glare Reduction

Harsh lighting can cause glare, leading to eye strain and decreased productivity. To minimize glare:

• Use fixtures with diffusers or anti-glare optics
• Position lights to avoid direct exposure to workers’ eyes
• Ensure uniform light distribution with no harsh contrasts

Reducing glare improves comfort, helping employees stay focused and reducing workplace fatigue.

Emergency Lighting

Industrial facilities must have emergency lighting for safety and compliance. Emergency lighting should:

• Provide at least 1 lux for escape routes
• Be battery-powered or connected to a backup generator
• Include illuminated exit signs for clear evacuation guidance

Following OSHA and EN 12464-1 standards ensures compliance and workplace safety in case of power outages or emergencies.

Zoning & Controls

Industrial spaces require flexible lighting controls to optimize energy use. Consider:

• Motion sensors to turn lights on only when needed
• Dimmable fixtures to adjust brightness based on daylight levels
• Automated systems for scheduling and remote control

Zoning and smart controls help lower energy bills while maintaining optimal lighting conditions for different work areas.

Proper industrial lighting follows specific guidelines for brightness, color temperature, glare control, emergency preparedness, and smart controls. A well-planned lighting system improves productivity, enhances safety, and reduces operational costs.

How Do You Calculate Industrial Lighting?

Getting industrial lighting right isn’t just about adding bright fixtures. It’s about precision, efficiency, and cost-effectiveness. Too little light creates safety risks, while too much wastes energy. Here’s how to calculate the ideal lighting setup for your facility.

Measure the Area

Start by calculating the square footage of the space:

• Multiply the length by the width to get the total area (sq. ft.).
• If the facility has different zones (storage, assembly, offices), measure each separately.
• Note ceiling height, as it affects fixture selection and light distribution.

Determine Lumen Needs

Lighting levels are measured in lux (lumens per square meter). Convert to lumens by multiplying the lux requirement by the area size. Recommended lux levels:

• General warehouse areas: 100–300 lux
• Assembly lines and workstations: 300–500 lux
• Precision work and inspections: 500–1000 lux
• Loading docks and security zones: 100–200 lux

To calculate total lumens needed:

Total Lumens = Area (sq. meters) × Required Lux

For example, a 500 sq. meter warehouse requiring 300 lux needs:

500 × 300 = 150,000 lumens

Pick the Right Fixtures

Choose fixtures based on ceiling height, beam angle, and lumen output:

• High bay lights for ceilings 20 feet and higher
• Low bay lights for ceilings under 20 feet
• Tube lights for aisles and shelving
• Vapor-proof or explosion-proof fixtures for harsh environments

Ensure each fixture has the right wattage-to-lumen ratio to maximize energy efficiency.

Optimize Placement

To prevent dark spots and glare:

• Space high bay lights evenly 20–30 feet apart
• Use narrow beam angles (60°-90°) for high ceilings
• Choose wide beam angles (120°-150°) for lower ceilings
• Position lights over workstations and pathways for even distribution

Run a Lighting Simulation

Before finalizing your setup, run a lighting simulation using tools like Dialux or Relux to:

• Verify uniform illumination
• Identify areas needing extra fixtures
• Optimize light angles and placement for efficiency

Calculating industrial lighting involves measuring the area, determining lumen needs, selecting the right fixtures, optimizing placement, and running a simulation. A well-planned lighting system saves energy, improves productivity, and enhances safety.

Lighting layout design for high bay industrial LED lighting

What Are the Different Types of Industrial Lighting?

Industrial lighting is more than just brightness—it’s about efficiency, durability, and safety. The right lighting solution depends on factors like ceiling height, environmental conditions, and energy efficiency needs. Let’s break down the different types of industrial lighting and their ideal applications.

LED High Bay Lights

High bay lights are designed for industrial spaces with ceilings over 20 feet. They provide uniform, powerful illumination for large areas like warehouses, manufacturing plants, and distribution centers.

• High lumen output ensures clear visibility in large spaces
• Available in various beam angles for different layouts
• Energy-efficient, cutting power costs by up to 70%
• Ideal for: Warehouses, factories, airplane hangars, and large commercial facilities

LED Flood Lights

Flood lights provide wide-area illumination for both indoor and outdoor industrial settings. They are used for security, perimeter lighting, and large open spaces.

• High-intensity brightness covers large outdoor spaces
• IP65/IP66-rated for weather resistance
• Can be mounted on walls, poles, or ceilings
• Ideal for: Outdoor yards, loading docks, parking lots, and sports complexes

LED Linear Lights

LED linear lights are long, strip-like fixtures used in assembly lines, workstations, and warehouse aisles. They provide even lighting for precise work environments.

• Flicker-free illumination reduces worker fatigue
• Slim and space-saving design for compact installations
• Available in suspended or surface-mounted options
• Ideal for: Production lines, conveyor systems, and indoor warehouse shelving

LED Street Lights

Industrial facilities often need outdoor roadway and parking area lighting for security and navigation. LED street lights provide long-lasting, low-maintenance illumination.

• Photocell and motion sensor options for energy savings
• High lumen-per-watt efficiency reduces electricity costs
• Designed for harsh weather conditions with IP65+ ratings
• Ideal for: Industrial roads, factory perimeters, and parking areas

Explosion-Proof Lights

Explosion-proof lighting is designed for hazardous environments where flammable gases, vapors, or dust may be present. These fixtures prevent sparks and overheating, ensuring workplace safety and compliance.

• Built with durable, impact-resistant materials
• Meets ATEX, IECEx, and UL safety standards
• Essential for hazardous locations like oil refineries and chemical plants
• Ideal for: Chemical plants, gas stations, offshore platforms, and industrial mines

LED Vapor Tight Lights

Vapor-tight lights are built for harsh environments exposed to moisture, dust, and extreme temperatures. They are sealed to prevent contamination and corrosion, making them ideal for wet and dirty conditions.

• IP66-rated for water and dust protection
• Corrosion-resistant materials for durability
• Used in cold storage, food processing, and outdoor applications
• Ideal for: Cold storage warehouses, food processing facilities, and wet environments

Choosing the right industrial lighting depends on environmental factors, energy efficiency, and operational needs. Whether you need high bay lights for warehouses, explosion-proof fixtures for hazardous zones, or LED flood lights for outdoor security, the right lighting enhances productivity, safety, and cost savings.

How to Choose Lighting for Harsh Industrial Environments?

Some industrial environments are far from friendly when it comes to lighting. Extreme temperatures, dust, moisture, and power surges can destroy ordinary fixtures, leading to frequent failures, increased downtime, and rising maintenance costs. If you’re dealing with factories, warehouses, oil refineries, or food processing plants, you need lighting that can withstand these tough conditions. Here’s what I recommend when choosing lighting for harsh industrial environments.

IP65/IP66 Rated Fixtures

Harsh environments often mean exposure to dust, water, and chemicals. If your facility is exposed to moisture or airborne debris, your lighting needs a high Ingress Protection (IP) rating.

• IP65-rated fixtures protect against dust and low-pressure water jets, making them suitable for indoor industrial environments like manufacturing plants, warehouses, and machine workshops.
• IP66-rated fixtures offer stronger water resistance, capable of withstanding heavy rain, high-pressure washdowns, and outdoor conditions. These are ideal for food processing plants, car washes, and oil refineries.
• Corrosion-resistant housings prevent rust and degradation in facilities with high humidity or chemical exposure.

High-Temperature Resistance

Industrial environments with extreme heat can shorten the lifespan of conventional lighting. High temperatures cause faster LED degradation, flickering, and complete failures if the fixture isn’t built for it.

• Heat-resistant LED fixtures can withstand temperatures above 50°C (122°F) without performance loss.
• Aluminum heat sinks and advanced thermal management systems help dissipate heat and prevent overheating.
• Best for steel mills, foundries, glass manufacturing plants, and high-temperature processing facilities.

Durable Construction

Industrial lighting fixtures need rugged designs to handle physical stress, impact, and vibrations.

• Die-cast aluminum housings provide excellent shock resistance and longevity compared to standard steel or plastic casings.
• Tempered glass or polycarbonate lenses prevent shattering in case of accidental impacts.
• Vibration-resistant mounts ensure stable installation in areas with heavy machinery or moving equipment.
• Ideal for mines, shipyards, transportation hubs, and high-vibration industrial zones.

Surge Protection

Industrial sites often experience power fluctuations and electrical surges caused by heavy machinery, high-voltage equipment, and unstable power grids. Without protection, surges can damage LED drivers and shorten fixture lifespan.

• Built-in surge protectors (10kV or higher) safeguard lighting systems from sudden voltage spikes.
• Industrial-grade surge protectors prevent electrical damage, reducing unexpected downtime and costly replacements.
• A must-have for power plants, oil rigs, heavy manufacturing sites, and industrial automation facilities.

Smart Controls

In harsh environments, energy efficiency is just as important as durability. Smart lighting controls improve performance while cutting operational costs.

• Motion sensors ensure lights only activate when needed, reducing wasted energy in areas with low traffic.
• Dimmable LED technology allows you to adjust brightness based on work schedules or natural daylight availability.
• Wireless remote monitoring systems let you control lighting across multiple locations, optimizing energy use.
• Perfect for warehouses, logistics centers, and 24/7 industrial operations looking to save on electricity.

Choosing the right lighting for harsh industrial environments requires waterproof and dustproof protection (IP65/IP66), heat resistance, impact durability, surge protection, and smart controls. These factors extend fixture lifespan, improve safety, and lower long-term maintenance costs.

What Type of Lighting Is Best Used for a Factory?

Factories need lighting that’s bright, uniform, and glare-free. Here’s what works best:
– LED High Bay Lights: Tall ceilings? These deliver powerful illumination.
– LED Linear Lights: Ideal for production lines—no shadows, just clear visibility.
– Tunable White Lighting: Adjusts color temperature to enhance worker focus.
– Motion Sensor Lighting: Cuts costs by turning on only when needed.

Conclusion

Choosing the right industrial lighting isn’t just about seeing better—it’s about working smarter. LEDs beat traditional lighting hands down in energy savings, durability, and maintenance costs. A well-planned lighting system enhances safety, productivity, and efficiency. Need expert advice on industrial lighting solutions? Reach out to us today, and let’s find the perfect lighting setup for your business!