Switching a factory to LED lighting takes on average between four weeks and six months, depending on the scale of the installation, the complexity of the environment, and the chosen approach. Smaller production halls with a simple retrofit can be tackled within a few weeks, while large-scale projects involving engineering processes, customization, and phased installation require considerably more time. The questions below provide a concrete picture of what determines the lead time and what you can expect per phase.
What factors determine the lead time of an LED conversion?
No conversion project is the same. The lead time depends on the size of the site, the type of installation, the degree of customization, and the availability of maintenance windows. A small workshop with standard luminaires can be converted in a few days, whereas a large production environment with special requirements demands months of preparation and execution.
The key factors at a glance:
- Surface area and number of luminaires: The larger the location, the more time the installation requires. Factories with hundreds of luminaires at great heights also require more logistical planning.
- Environment type: Extreme conditions such as high temperatures, corrosive atmospheres, or explosion hazards require certified luminaires and extra precautions during installation.
- Availability of downtime moments: Factories that operate 24/7 have limited installation capacity. This necessitates phased planning.
- Engineering path: Custom lighting designs, lighting calculations, and technical coordination extend the preparation time but improve the final result.
- Permits and standards: ATEX applications or installations in regulated environments require additional documentation and approvals.
Starting the engineering phase in time prevents unnecessary delays during execution. In industrial LED projects, proper preparation is the decisive factor for meeting the schedule.
How long does the engineering phase for an industrial LED project take?
Two to eight weeks,that is the typical timeframe, depending on the complexity of the installation and the number of parties involved. During this phase, lighting calculations are performed, luminaires are selected, wiring plans are drawn up, and technical coordination takes place with the client.
For standard projects in production environments, a shorter engineering phase is sufficient, especially if the existing infrastructure is largely retained. In complex environments,such as steel mills, climate chambers, or sites with Extreme corrosion, a more thorough engineering process is required. This includes determining the appropriate IP and IK ratings, selecting luminaires with the right thermal properties, and matching the light color to the task at hand.
Design flaws can lead to reinstallations, suboptimal light output, or premature failure of luminaires. Therefore, invest in a reliable lighting design before installing the first light luminaire,which will save you significantly more in the long run than it costs.
Can a factory continue to operate as usual during the transition?
Yes, in most cases. A phased approach makes it possible to carry out the installation per zone, hall, or production line, so that production in the rest of the location can continue undisturbed.
Phased installation is the standard working method for industrial LED projects in active environments. The installer works outside of production hours, during planned maintenance stops, or in zones that are temporarily out of service. Good coordination with the operations manager or maintenance manager is essential in this regard to minimize downtime.
In environments with specific risks,such as ATEX zones or high-temperature locations,additional safety protocols apply during installation. This may extend the installation time per zone, but does not necessarily affect overall production. A detailed installation plan tailored to the factory’s production schedules prevents unnecessary disruptions.
What is the difference between a retrofit and a complete reinstallation?
In a LED retrofit, the existing luminaire housings are retained and only the light sources and drivers are replaced with LED components. In a complete reinstallation, the old luminaires are completely removed and replaced with new LED luminaires, including any necessary adjustments to the wiring and mounting points.
The choice between the two options has a direct impact on the turnaround time and the investment:
- LED retrofit: Faster and more cost-effective to implement. Suitable if the existing enclosures are still in good condition and the positioning of the luminaires meets current lighting requirements. The turnaround time is significantly shorter.
- Complete reinstallation: It requires more time and investment, but offers the opportunity to fully optimize the lighting design. New luminaire positions, higher light output, better uniformity, and luminaires specifically designed for the environment. This is the recommended choice for outdated infrastructure or environments with demanding requirements.
Especially in the heavy industry a complete reinstall is often the wiser choice in the long run. Retrofit solutions do not always offer the technical performance required in demanding environments involving vibration, heat, or aggressive substances. A new luminaire designed for specific conditions performs longer and more reliably than a refurbished housing with a new light source.
How fast is the payback period after an industrial LED conversion?
The payback period is typically between two and five years, depending on the energy consumption of the old system, the number of operating hours per year, and the size of the investment. Factories that operate 24/7 with outdated HID or fluorescent lighting achieve the shortest payback period.
The savings come from several sources. LED luminaires consume up to 70 percent less energy than traditional industrial lighting. In addition, maintenance costs are lower due to the longer lifespan of LEDs and the greater reliability of modern luminaires. Fewer lamp replacements at great heights also mean less downtime and lower costs for aerial work platforms or scaffolding.
In the Netherlands, there are also tax incentives available for energy-efficient investments, such as the Energy Investment Allowance (EIA). This can significantly reduce the net investment and shorten the payback period. It is wise to also identify potential grant opportunities during the project planning phase.
Practical example: VPK Paper
VPK Paper, a producer of corrugated board and paper, wanted to convert the lighting in its paper mills in Belgium to LED. In and around the paper machine, the temperature rises to +120 °C in the most extreme cases, with steam and very high humidity. Several LED solutions tried earlier, from different suppliers, did not last there. A trial with the Snapper HT from JEL did succeed and formed the basis for the further rollout. JEL handled the lighting design and engineering, designed the installation and supplied 98 Snapper HT luminaires in AC version, which achieve 100 to 200 lux in the machine at 35 W per luminaire.
Every failed trial cost time, money and confidence in the switch to LED. In the total lead time of a conversion, a series of trial periods like this can weigh more heavily than the installation itself.
A targeted trial under the real conditions adds time at the start, but prevents a complete rollout from having to be repeated later. In environments with heat and moisture, proof up front is therefore not a delay, but the shortest route to an installation that keeps working.
Read more about the VPK Paper project
How JEL Products Can Help with Your LED Conversion
JEL Products guides industrial organizations through the transition to LED lighting from start to finish. Whether it’s a simple retrofit or a completely new lighting project in a demanding environment,we deliver more than just luminaires.
What to Expect During an LED Conversion Project:
- Professional lighting design and lighting calculations tailored to the specific environment
- Selection of luminaires suitable for extreme conditions such as high temperatures and corrosion, with referral to a certified Ex manufacturer for ATEX zones
- Assistance with applying for subsidies and tax benefits such as the EIA
- Complete project execution, including foundations, light poles, installation, and commissioning
- ISO 9001 and VCA**-certified procedures for quality and safety in the workplace
Do you want to know how long the switch will take in your specific situation and what the expected savings are? Please contact JEL Products for a no-obligation consultation.
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