Last updated on Mar 21, 2024

What are the best practices for energy-efficient lighting in manufacturing plants?

Lighting is one of the most important factors in ensuring the safety, quality, and productivity of a manufacturing plant. However, lighting can also consume a significant amount of energy and contribute to the carbon footprint of the industry. Therefore, it is essential to adopt the best practices for energy-efficient lighting in manufacturing plants, which can reduce costs, enhance performance, and support environmental sustainability. In this article, we will discuss some of the key aspects of energy-efficient lighting, such as lighting design, technology, control, and maintenance.

1 Lighting design

The first step to achieve energy-efficient lighting is to design the lighting system according to the specific needs and characteristics of the plant. This involves assessing the lighting requirements for different tasks, areas, and times of the day, and choosing the appropriate light levels, color temperatures, and distribution patterns. A good lighting design should also consider the natural light sources, such as windows and skylights, and optimize their use and integration with the artificial lighting. A well-designed lighting system can reduce the energy consumption by up to 50% compared to a standard system.

Add your perspective

Yashar Abbasnejad

🚪Kitchen Cabinet Specialist🚪Design Consultant🚪Technical & Production Expert
Report contribution
💡One notable project involved redesigning the lighting system in a cabinet manufacturing facility to reduce energy consumption while improving visibility and productivity. 💡We replaced outdated fluorescent fixtures with energy-efficient LED lighting, strategically positioned to minimize shadows and glare on work surfaces. Additionally, we incorporated daylight harvesting sensors and motion detectors to automatically adjust light levels based on natural light and occupancy. 💡This comprehensive approach not only reduced energy costs but also created a more comfortable and productive work environment for employees.

Like

2 Lighting technology

The second step to achieve energy-efficient lighting is to select the most suitable lighting technology for the plant. The lighting technology refers to the type of lamps, fixtures, and ballasts that are used to produce and deliver the light. The most common types of lighting technology for manufacturing plants are fluorescent, high-intensity discharge (HID), light-emitting diode (LED), and induction. Each of these technologies has its own advantages and disadvantages in terms of energy efficiency, lifespan, performance, and cost. Generally, LED and induction are the most energy-efficient and durable options, while fluorescent and HID are more widely used and cheaper.

Add your perspective

Yashar Abbasnejad

🚪Kitchen Cabinet Specialist🚪Design Consultant🚪Technical & Production Expert
Report contribution
🔅One significant project involved implementing advanced LED lighting systems throughout a large-scale production facility. 🔅We conducted extensive research to select the most suitable LED fixtures, considering factors like brightness, color temperature, and energy efficiency. By strategically installing these fixtures with motion sensors and daylight harvesting controls, we optimized energy usage while ensuring optimal lighting conditions for different areas of the plant. 🔅This investment not only reduced energy consumption and operating costs but also improved visibility, safety and productivity on the factory floor.

Like

3 Lighting control

The third step to achieve energy-efficient lighting is to implement the lighting control system that can adjust the light output according to the actual demand and conditions. The lighting control system can include various components, such as sensors, timers, dimmers, switches, and network devices, that can monitor and regulate the lighting operation. The lighting control system can provide several benefits, such as reducing the energy waste, improving the comfort and safety, and extending the lifespan of the lamps. The lighting control system can save up to 30% of the energy consumption compared to a constant lighting system.

Add your perspective

Yashar Abbasnejad

🚪Kitchen Cabinet Specialist🚪Design Consultant🚪Technical & Production Expert
Report contribution
💠In one particular project, we integrated advanced lighting controls featuring occupancy sensors and programmable schedules. 💠By strategically placing these controls throughout the facility, we optimized lighting usage based on occupancy and natural light levels. For instance, in areas with intermittent activity, such as storage areas or corridors, lights would automatically dim or turn off when not in use, significantly reducing energy consumption. 💠This approach not only improved energy efficiency but also extended the lifespan of the lighting fixtures, resulting in long-term cost savings and sustainability benefits for the manufacturing plant.

Like

4 Lighting maintenance

The fourth step to achieve energy-efficient lighting is to perform the regular lighting maintenance that can ensure the optimal performance and quality of the lighting system. The lighting maintenance involves inspecting, cleaning, repairing, and replacing the lamps, fixtures, ballasts, and control components, as well as measuring and evaluating the light levels and quality. The lighting maintenance can prevent the deterioration and failure of the lighting system, which can affect the energy efficiency, safety, and productivity of the plant. The lighting maintenance can also identify the opportunities for improvement and upgrade of the lighting system.

Add your perspective

Yashar Abbasnejad

🚪Kitchen Cabinet Specialist🚪Design Consultant🚪Technical & Production Expert
Report contribution
🔧In one project, we implemented a proactive lighting maintenance program where we regularly inspected, cleaned and repaired lighting fixtures to ensure optimal performance and energy efficiency. 🔧This proactive approach not only helped us identify and address issues promptly but also extended the lifespan of the lighting system, reducing the need for frequent replacements and associated costs.

Like

5 Lighting audit

The fifth step to achieve energy-efficient lighting is to conduct the lighting audit that can assess the current state and performance of the lighting system and provide the recommendations for improvement. The lighting audit is a comprehensive and systematic evaluation of the lighting system, which involves collecting and analyzing the data on the lighting design, technology, control, and maintenance, as well as the energy consumption, cost, and savings. The lighting audit can help to identify the gaps and problems in the lighting system, as well as the potential solutions and benefits. The lighting audit can also help to plan and implement the lighting retrofit or upgrade projects.

Add your perspective

Yashar Abbasnejad

🚪Kitchen Cabinet Specialist🚪Design Consultant🚪Technical & Production Expert
Report contribution
🎛During one such audit, we meticulously assessed the lighting systems across the facility, examining factors like illuminance levels, fixture types and energy consumption. 🎛Using specialized tools and techniques, we identified areas where lighting could be optimized to reduce energy usage without compromising safety or productivity. This involved replacing outdated fixtures with energy-efficient alternatives, implementing lighting controls such as occupancy sensors and daylight harvesting, and strategically positioning lighting to minimize waste.

Like

6 Lighting retrofit or upgrade

The sixth and final step to achieve energy-efficient lighting is to execute the lighting retrofit or upgrade projects that can improve the lighting system according to the findings and recommendations of the lighting audit. The lighting retrofit or upgrade projects can involve replacing or modifying the existing lamps, fixtures, ballasts, and control components with more energy-efficient and high-quality ones, as well as redesigning or reconfiguring the lighting system to optimize the light levels and distribution. The lighting retrofit or upgrade projects can result in significant energy savings, performance improvement, and environmental benefits for the plant.

Add your perspective

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

Add your perspective

Yashar Abbasnejad

🚪Kitchen Cabinet Specialist🚪Design Consultant🚪Technical & Production Expert
Report contribution
🏭In a recent project focused on optimizing energy-efficient lighting in our manufacturing plant, we conducted a thorough assessment to identify opportunities for improvement. 🔗One significant change we implemented was transitioning from traditional fluorescent lighting to LED fixtures. Not only did this reduce energy consumption significantly, but it also enhanced visibility and safety on the production floor. 🔗We installed occupancy sensors and timers to ensure that lights were only active when needed, further minimizing wastage. 🔗Regular maintenance schedules were established to promptly address any issues and ensure the continued efficiency of our lighting system.

Like

Production Management

Rate this article

We created this article with the help of AI. What do you think of it?

It’s great It’s not so great

Report this article

See all

What are the best practices for energy-efficient lighting in manufacturing plants?

1

2

3

4

5

6

7

1 Lighting design

2 Lighting technology

3 Lighting control

4 Lighting maintenance

5 Lighting audit

6 Lighting retrofit or upgrade

7 Here’s what else to consider

Production Management

Rate this article

Thanks for your feedback

More articles on Production Management

More relevant reading