Lighting control is a system that automatically regulates lighting in a factory based on presence, daylight, schedules, or external signals. Instead of lamps constantly burning at full power, lighting control adjusts the light level to what the situation requires. This results in significant energy savings while simultaneously increasing safety and work comfort. In this article, we answer the most frequently asked questions about industrial lighting control—from available systems to legal requirements.
What forms of light control are used in factories?
There are four main forms applied in factories: presence detection, daylight control, time-controlled regulations, and manual dimming via protocols such as DALI or 0-10V. These forms are often combined into one integrated system, depending on the space, usage, and desired degree of automation.
Each form has a specific application area within the production environment:
- Presence detection The lighting automatically turns on with motion or human presence and turns off or dims after an adjustable period of inactivity. Suitable for storage areas, corridors, and zones with intermittent use.
- Daylight control Sensors measure the amount of natural light and adjust the artificial lighting accordingly. Particularly effective in halls with skylights or facade windows.
- Timed controls: Lighting follows a fixed schedule, adapted to shift work or opening hours. Easy to program and reliable in environments with fixed routines.
- Dimmable LED systems via protocol: Via DALI, 0-10V, or other protocols, fixtures are controlled individually or in groups, allowing for granular control over each zone in the factory.
In heavy industry, these systems are often combined with extensive lighting expertise in engineering trajectories to fully align the installation with business processes.
How does presence detection work with industrial lighting?
Sensors that register motion or heat form the basis of presence detection. Based on these signals, the light level is automatically controlled. In industrial environments, PIR sensors (passive infrared) and HF sensors (high-frequency radar) are primarily used, as they work reliably in the presence of dust, vibrations, and temperature fluctuations.
The difference between the two sensor types is practically relevant for factory environments:
- PIR sensor detect heat differences and are suitable for spaces with clear movement patterns. They are more sensitive to obstacles in the line of sight and less suitable for environments with many heat sources.
- HF radar sensors They also detect minimal movements through walls or structures and work more reliably in environments with dust, high temperatures, or obstacles. They are therefore the preferred choice for heavy industrial applications.
In practice, sensors are set with a sensitivity threshold and a deactivation delay. This way, the lighting remains active as long as someone is present, but after an adjustable period of inactivity, it returns to a low standby level instead of turning off completely. This is safer than complete deactivation in active production environments.
What is the difference between DALI and 0-10V lighting control?
Both protocols are used for dimming LED fixtures, but they fundamentally differ in how they communicate. DALI is a digital, bidirectional protocol that allows for individual addressing of fixtures. 0-10V is an analog signal that dims a group of fixtures simultaneously without feedback.
DALI: digital precise control
DALI (Digital Addressable Lighting Interface) controls each fixture individually via a digital network. The controller can receive status updates, detect faults, and program lighting scenes per zone. This makes DALI suitable for complex factory environments with many zones, changing activities, and a need for detailed monitoring and energy reporting.
0-10V: simple and robust
With 0-10V control, an analog voltage signal from 0 to 10 volts runs to the fixtures. At 10V, they operate at full power; at 1V, at minimum power. The system is simpler and cheaper to install, but offers no feedback and addresses fixtures by group. In industrial environments with fixed zones and less need for individual control, 0-10V is a reliable and cost-effective choice.
The choice between both protocols depends on the complexity of the installation, the desired level of control, and the budget. For large sites or Marine installations With multiple zones and 24/7 operations, DALI is typically the better long-term investment.
How much energy does lighting control save in a manufacturing facility?
On top of the savings already realized by switching to LED, lighting control in a production facility can yield an additional 30 to 60 percent in energy savings. The exact savings depend on the type of control, space occupancy, and the amount of available daylight.
The greatest savings are achieved in zones with intermittent use, such as storage areas, loading docks, and corridors. In production areas that are occupied 24/7, savings via presence detection are more limited, but daylight control and optimized dimming curves still provide a significant reduction there.
Lighting control also extends the lifespan of LED fixtures. Fixtures that operate at full power for fewer hours last longer, reducing replacement costs and maintenance. This is a relevant advantage in industrial environments with hard-to-reach installations. More information on the financial aspects of energy-efficient lighting investments can be found on the page about Energy investment tax credit.
What environmental factors determine which system is suitable?
Not every environment has the same requirements. The choice of a lighting control system is determined by factors such as temperature, dust, vibrations, available daylight, occupancy patterns, and the nature of the work. A system that works perfectly in an office environment may fail in a production hall with extreme conditions.
The key environmental factors at a glance:
- Temperature: Sensors and control electronics must withstand the operational temperature range of the environment. Different requirements apply in steel mills or climate chambers than in a standard production hall.
- Dust and moisture: The IP protection rating of sensors and fixtures must match the environmental conditions. Higher IP classes are required in dusty or wet environments.
- Tremors In environments with heavy machinery or vehicles, sensors and fixtures must withstand constant mechanical stress.
- Daylight penetration Halls with many windows or skylights benefit the most from daylight control. In fully enclosed production areas, daylight control has little added value.
- Occupancy pattern With fixed shifts, a time-based system is often sufficient. With variable staffing, presence detection is more effective.
In environments with explosion hazards or aggressive chemical exposure, additional ATEX requirements apply to all electrical components, including the lighting control.
When is lighting control mandatory or legally required?
Lighting control is a legal requirement in the Netherlands for new construction and major renovations of utility buildings, as mandated by the Building Decree and the Energy Performance of Buildings Directive (EPBD). New industrial buildings must meet energy performance requirements, and in many cases, automatic lighting control is necessary to achieve these standards.
This concretely means that buildings above a certain size must use presence detection and daylight control in technically feasible areas during new construction or major renovations. The exact requirements depend on the type of building, its intended use, and the scope of the work.
In addition, the government stimulates lighting control through fiscal regulations such as the Energy Investment Allowance (EIA), which makes investments in recognized energy-saving systems partially tax-deductible. This makes lighting control not only a legal requirement in certain cases but also a financially attractive choice in situations where it is not mandatory.
For companies operating in sectors such as offshore or heavy industry, additional standards apply through sector-specific safety regulations, where lighting and its control are part of the broader safety requirements for the installation.
Examples from practice: DFDS Terminal Lighting
A concrete example of how lighting control and environmental factors come together is the project at DFDS, a large Ro-Ro terminal where lighting must be operational 24/7 under harsh maritime conditions. The technical challenges were significant: high salt load, constant vibrations from moving equipment, varying occupancy patterns on the quay, and the necessity to ensure adequate lighting levels for safe loading and unloading operations at any time of day.
During the design phase, fixtures with a high IP protection rating and a robust housing resistant to the mechanical stress of terminal traffic were selected. The lighting zoning directly aligned with the terminal's operational logic: active quay areas received a different light control strategy than the storage zones, where varying occupancy made presence detection a viable option. Maintenance was an explicit design consideration—fixtures were positioned for replacement and inspection to be feasible without interrupting terminal operations.
The learned lesson, directly applicable to industrial lighting control in general: a control system is only as good as the environmental specifications it is tuned to. Standard solutions fail in harsh outdoor environments. More examples of similar projects can be found at projects page.
How JEL Products Helps with Industrial Lighting Control
JEL Products offers more than just high-quality LED fixtures for harsh industrial environments. As a specialist in comprehensive lighting solutions, JEL Products works with you to determine the right lighting control system for every specific situation—from selecting the appropriate protocol to integrating the system with existing installations.
Here's what JEL Products specifically offers in the area of lighting control:
- Advice on the most suitable control protocol (DALI, 0-10V, or alternative) for the specific environment and use
- Lighting design that integrally incorporates light control in calculations and zoning
- Fixtures compatible with standard control protocols and resistant to extreme environmental conditions
- Guidance on the subsidy process for energy-saving lighting investments
- Full project management: from engineering and installation to commissioning and maintenance
Whether it’s a new production facility, an existing system that needs to be optimized, or an environment with extreme requirements—JEL Products works with you, drawing on its technical expertise and practical experience. Feel free to contact us via the contact page for a no-obligation discussion about the possibilities for your situation.