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More light — more benefits

Больше света — больше выгодыReplacement of bulbs with LED lighting fixtures is probably one of the first measures aimed at reducing energy consumption taken by companies. But what exactly should the lighting fixture be to illuminate production lines?

Slow replacement

The first LEDs appeared in manufacturing plants in the form of LED indicators on control panels. Later, machine builders used LED-technology in displays. Concurrently, another area of focus, namely lighting technologies, started to develop, and today LEDs are widely used for illumination of production shops, warehouses and other facilities.

There are also explosion proof versions. They are widely used in working environments involving paint-and-lacquer materials, combustible gases and refinery products in mines, refineries, and oil and gas production facilities.

It should be noted that today the segment of commercial and industrial lighting is 36% of the overall total and is gradually increasing. This growth is due to the fact that LED lighting fixtures are gradually replacing traditional sodium and metal-halogen lamps previously considered to be highly energy-saving.

As they say in the Optogan Group (the largest producer of LED lighting fixtures in Russia), the leading positions on the global LED-lighting market are occupied by industrial and office solutions, as well as by architectural lighting. The share of retrofit lamps (having a well-known pear-shape) on the LED lighting market in 2011 was 23%, and retrofit lamps with Е27 cap – 9%.

Fulfilling wishes

It would seem that industrial LED lighting fixtures should be powerful and more or less protected from aggressive environments, and hence, any outdoor version can perfectly meet the challenge of industrial lighting (in fact, some vendors present their products as having those qualities).

But a standard outdoor item with an appropriate protection of a luminaire against rain and dust may be not enough for harsh conditions of high temperatures, chemical contaminants in the air and electromagnetic radiation. Many companies design special industrial light sources to cope with heat, dust and chemicals.

There are also explosion proof LED lighting fixtures. They are widely used in environments when working with paint-and-lacquer materials, combustible gases and refinery products in mines, refineries, and oil and gas production facilities.

“Production equipment with a high power rating creates serious electrical line noise (especially at start-up). Therefore, one of the main characteristics that ensure smooth operation and save LED lighting fixtures efficiency is reliability and stability of the LED driver against unstable line voltage”, says Vadim Dadyka, Director General of AtomSvet LLC.

Vadim Dadyka, Director General of AtomSvet LLC:

“Energy consumption of Russian enterprises is 5-10 times higher than that in developed countries. Energy saving technologies are particularly topical for heavy industry and large manufacturing complexes where ignoring them leads to huge financial losses. A competent approach to organization and implementation of complex energy-saving programmes will guarantee good results. 35-40% is a realistic figure for savings in energy costs and has already been achieved by many enterprises. Moreover, energy-saving LED lighting plays an important role in energy saving.

I would emphasize that cost saving when switching to energy-saving lighting should be considered as additional investment in the development of production on any scale. According to recent market tendencies, worldwide, LED lighting started to replace traditional light sources, including fluorescent lamps. This is due to the fact that their energy efficiency is twice as high as that in fluorescent lamps and 10 times higher than in incandescent lamps. LED lighting fixture lifetime is more than 50,000 hours, which is 50 times longer than with incandescent lamps. The LED performance coefficient is about 45%, that of incandescent lamps is much less – only 5-10% (the remaining 90-95% “heat the environment”). Another advantage of LED light sources is their environmental safety and ease of recycling as LEDs do not contain mercury, lead or other harmful substances.

If we talk about a comprehensive approach to industrial lighting refurbishment then the logical arguments are the following (as an example let us consider the economic effect of transition to LED lighting fixtures in a standard industrial shop): ROI analysis of transition to LED lighting shows that AtomSvet® LED lighting both pays back its cost and starts bringing substantial profit in less than 3 years. Over 5 years a shop lighting system consisting of 100 LED luminaires can bring more than 2 million RUR (profit investment ratio is 23.73% per annum, which is at least twice as high as any bank deposit rate). On top of that, it saves labour and financial resources involved in lamp replacement, and no costs are incurred on 1st hazard class waste storage and recycling”..

Greg Sebaskiy, the chief executive officer of Philips North America, said in an interview that the global LED market will grow by about 40% by the end of the year.

According to him, the turning point will start with the appearance on the market of 60 W Philips LED lamps – the equivalents of incandescence lamps costing $10. As a result, the sales will grow from 25% during the last year to 50% by 2015. According to Sebasky, consumers start to consider lamps as durable goods. Philips produces LED products with controlled lighting levels that allow house owners to save approximately $250 on electricity consumption annually.

A light spot on reputation

However, not every enterprise will need the whole range of hazard-proof devices. Less dusty assembly plants may need cheaper and simplified models, but all protection parameters can be provided only by a respected manufacturer with good reputation which is not so common in the market. As in other segments of LED lighting industrial lighting fixtures sellers often offer their customers Chinese forgeries under European brands.

It is extremely difficult to distinguish between such devices and brand products assembled in China: a buyer can only “guess” by the product price being too low. And the fact that a cheap luminaire is of poor quality appears only during operation when it stops working much earlier than expected. Therefore, the choice of industrial lighting fixtures should be made with awareness of the necessary technical parameters, and with understanding that a cheapskate pays twice.

by Julia Rebrunova

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Video of the manufacturing process and advantages of AtomSvet® LED lighting fixtures

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