What lighting is used in the pulp and paper industry?

Lighting in the paper and pulp industry is a specialized field. Paper mills combine extreme humidity, chemical vapors, fine dust, and sometimes hazardous areas, meaning standard industrial fixtures simply do not suffice here. The right choice depends on the specific environmental conditions of each production zone. In this article, we answer the most frequently asked questions about lighting in this sector.

What conditions make lighting in paper mills so challenging?

Paper mills are one of the most demanding environments for lighting installations. The combination of high humidity, chemical vapors from the pulping process, cellulose dust, and mechanical vibrations from heavy machinery creates an environment that rapidly deteriorates fixtures. In addition, many paper mills operate continuously, meaning maintenance on lighting can rarely be scheduled during a quiet time.

Specifically, installers and administrators have to deal with:

Humidity regularly reaching %, with condensation on fixtures
Corrosive chemicals such as chlorine and alkalis used in pulp bleaching
Fine cellulose dust that accumulates in fixtures and vents
Strong vibrations from paper rollers, pumps, and conveyor belts
High ambient temperatures near drying cylinders and steam installations
Limited accessibility for maintenance due to ongoing production

All these factors combined mean that lighting in the paper industry must be specifically selected for robustness, degree of protection, and resistance to chemical corrosion. Anyone who chooses a standard industrial fixture here risks rapid failure and high maintenance costs.

Which type of LED fixtures is suitable for the paper and pulp industry?

For the paper and pulp industry, LED fixtures with a minimum of IP65 protection are required, preferably IP66 or higher, combined with high impact resistance (IK rating) and corrosion-resistant housing material. In zones with intensive chemical use, fixtures made of stainless steel or with special coatings are the recommended choice.

The selection varies per production location. In the pulp preparation and bleaching department, where chemical vapors are heaviest, stainless steel or a polycarbonate enclosure with high IP ratings is the norm. In the drying department, temperature resistance plays a greater role. Near paper rollers and conveyor belts, a high IK rating is essential to prevent damage from vibrations and mechanical impacts.

For high installation heights in production areas, powerful LED high bays or floodlights are required that guarantee a sufficient light level on the work floor without requiring frequent maintenance. industrial LED floodlights are a widely used solution in these types of environments due to their high light output and long lifespan.

When is ATEX lighting mandatory in a paper mill?

ATEX lighting is mandatory in areas where an explosive atmosphere may occur. In paper mills, this is the case in locations where flammable dust clouds of cellulose, wood, or paper residues can form, or where flammable gases are released during chemical processes. These are so-called ATEX zones, classified based on the frequency and duration of the hazard.

The ATEX Directive (2014/34/EU) obliges manufacturers and operators to classify hazardous areas and to use exclusively certified equipment approved for that specific zone. For dust explosions, zones 20, 21, and 22 apply; for gas explosions, zones 0, 1, and 2 apply.

In practice, the most high-risk locations in a paper mill are the storage areas for dry cellulose dust, the surroundings of paper cutting machines, and certain sections of the chemical plants. Explosion-proof lighting here is not an option, but a legal obligation. Failure to comply with this leads not only to safety risks, but also to liability in the event of incidents.

What are the advantages of LED compared to conventional lighting in the pulp industry?

LED lighting offers significant advantages in the pulp and paper industry compared to conventional light sources such as high-pressure sodium or fluorescent lamps. The biggest difference lies in lifespan, energy consumption, and maintenance frequency, three factors that directly impact operational costs in a 24/7 production facility.

Practical benefits of LED in the pulp industry at a glance:

Longer lifespan High-quality LED fixtures last significantly longer than conventional light sources, which drastically reduces the number of replacement moments.
Low energy consumption: LEDs consume up to % less energy for an equivalent light output, which results in substantial cost savings in large production halls.
Direct boot: LED reaches full light level immediately, without warm-up time. This is relevant for emergency lighting or when restarting after a power outage.
Better light color: A higher color rendering index (CRI) makes it easier to visually perform quality controls on paper and pulp.
Less heat emission: LEDs emit less heat than conventional lamps, which eases climate control in warm production areas.
Vibration resistant: LED has no filament or fragile parts that are affected by vibration, which increases reliability.

Anyone considering making the switch can benefit from financial arrangements such as the Energy investment allowance (EIA)., making part of the investment tax-deductible.

What standards and certifications apply to lighting in the pulp and paper industry?

For lighting in the paper and pulp industry, the IP rating and IK rating are the most direct technical requirements. The IP rating (Ingress Protection) indicates the extent to which a fixture is protected against dust and moisture. In damp production areas, a minimum IP65 rating is required; in environments with direct spray exposure, IP66 or IP67 applies. The IK rating indicates the mechanical impact resistance, which is relevant in environments with vibrations and moving machine parts.

In addition, ATEX certification requirements apply in explosion-hazard zones. Luminaires must be certified for the specific zone classification of the area in question. For corrosive environments, additional material requirements apply, such as the use of stainless steel or coated aluminum housings. More background on what IP and IK ratings mean in practice can be found on the page about IP and IK ratings.

How does the replacement of old lighting proceed in an operating paper mill?

Replacing lighting in a continuously operating factory requires careful planning. Downtime is costly in the paper industry, which means replacement work must be carried out in phases, often during short maintenance stops or outside peak production hours.

A structured approach typically looks like this:

Inventory and light measurement: Map out the current situation, including lighting levels per zone, luminaire types, and the condition of the installation.
Lighting Design: Determine, based on standards and operational requirements, which luminaires are required per zone, including ATEX zones.
Phase planning: Divide the factory into zones that can be replaced individually without interrupting production.
Phase-by-phase installation: Perform the replacement zone by zone, preferably during scheduled maintenance stops.
Commissioning and Measurement After installation, check whether the lighting levels meet the requirements and record this.

Special attention must be paid to the accessibility of luminaires at great heights. In paper mills, luminaires are often hung at ten meters or more, above active machinery. Proper planning and the right equipment are then essential to work safely.

Practical example: VPK Paper

VPK 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 generation and very high humidity. None of the LED solutions tried earlier lasted. After several trials with different suppliers, a trial with the Snapper HT succeeded and formed the basis for the roll-out: 98 Snapper HT luminaires in AC version, 35 W per luminaire. The lighting design was verified against EN 12464-1 and delivers 100 to 200 lux in the machine, with a uniformity between 0.40 and 0.60.

In a paper mill, heat and moisture act on a luminaire at the same time: heat shortens the service life of the LED and driver, and steam and moisture find every weak point in the seal. A luminaire that looks suitable on paper can still fall short there. A trial under real conditions, before the whole mill is converted, limits that risk and makes replacement in a running mill easier to plan.

How JEL Products helps with lighting in the paper and pulp industry

JEL Products not only supplies luminaires, but also assists in thinking through the complete lighting solution for demanding industrial environments. For the paper and pulp industry, that specifically means:

Selection of luminaires based on the specific environmental conditions per production area
Lighting for the areas outside the ATEX zones, with referral to a certified Ex manufacturer for the zones themselves
Lighting design including calculation of lighting levels per zone
Delivery of corrosion-resistant stainless steel fixtures for chemically demanding environments
High-temperature solutions for areas near drying cylinders and steam installations, see also the page about High-temperature lighting
Guidance for phased replacement in an operational plant
Support with subsidy and tax schemes such as the EIA

Do you want to know which lighting solution suits your paper mill or pulp plant? Get in touch with the specialists at JEL Products for a no-obligation consultation.

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Which lighting is used in the paper and pulp industry?