For a production hall Industrial LED lighting the most suitable choice. LED fixtures combine high light output, a long lifespan, and low energy costs with the robustness required by a production hall. Which type of fixture is precisely suitable depends on the zone, the existing risks, and the requirements for the degree of protection. This article answers the most frequently asked questions about lighting in production environments.
What lighting requirements apply in a production hall?
In a production hall, the lighting must comply with the NEN-EN 12464-1 standard, which prescribes minimum illuminance levels per type of workstation. For general production areas, the lower limit is 300 lux, while for precision assembly work or quality control, this increases to 500 or even 1000 lux. In addition, uniformity, glare limitation, and color rendering (Ra value) are determining factors.
Besides the illuminance itself, other requirements also play a role. The color rendering index (Ra) must be at least 80 for workplaces where color discrimination is relevant, such as in quality control or reading color-coded pipes. An excessively low Ra value increases the chance of errors. Light color in Kelvin affects the work atmosphere and alertness of employees: neutral white (4000K) is the standard in most production environments.
Furthermore, emergency lighting is mandatory on escape routes and near dangerous machinery. The lighting must be resistant to the environmental conditions in the hall, such as dust, moisture, vibrations, and temperature fluctuations.
What makes LEDs better than traditional lighting in a manufacturing environment?
LED lighting performs better than traditional light sources such as fluorescent tubes, high-pressure sodium, or metal halide lamps in a production environment on virtually all relevant points: lower energy consumption, immediate full light output upon switching on, longer lifespan, and less maintenance. This difference is particularly noticeable in environments that operate 24/7.
Traditional light sources require a warm-up period before burning at full power. With frequent on-off cycles, such as with motion sensors or shift changes, this greatly accelerates wear and tear. LED fixtures do not have this problem and are immediately at full brightness. Furthermore, LED fixtures produce less heat in the light beam, which is a relevant advantage in warmer production environments.
The energy savings are significant. LEDs typically consume 50 to 70 percent less electricity than equivalent traditional light sources at the same lumen output. In production environments with large floor areas and many operating hours, the annual savings quickly add up. The higher purchase price of LED fixtures is therefore recouped within a few years in most cases.
What type of LED fixture is suitable for which zone in a production hall?
In a production hall, different zones can be distinguished, each with its own lighting needs. High bay fixtures are suitable for high halls above five meters, floodlights or panel fixtures are suitable for lower workstations and office spaces, and targeted LED floodlights used on specific workstations or outdoor areas adjacent to the hall.
An overview of the most common zones and their corresponding fixture types:
- High production hall (ceiling height over 5 meters): LED high bay with a wide or narrow beam angle depending on the working height and the desired light distribution at floor level.
- Workshop or assembly room location: LED lowbay or flat beam light for even, non-glare light distribution at workbench height.
- Warehouse or storage area Linear LED fixtures or high bays targeted at aisles for good visibility of labels and shelves.
- Loading and unloading dock Robust LED fixtures with a high IP rating, resistant to outdoor conditions and traffic.
- Workstations for precision work Task lighting in addition to general lighting, with a high CRI value.
- Machines and cranes: Specific LED work lights that are resistant to vibration and mechanical stress.
What IP and IK classes are needed for production hall lighting?
For lighting in a production hall, the minimum requirement is IP65 for areas where dust or splashing water is present. In wetter or harsher environments, such as near chillers or washing systems, IP66 or IP67 is required. The IK class indicates mechanical impact resistance and must be at least IK08 in areas where machines, forklifts, or other vehicles operate.
Of IP and IK classes are not a formality but a direct reflection of the fixture's lifespan in practice. A fixture with too low a protection rating in a dusty environment will fail prematurely, leading to higher maintenance costs and unexpected downtime. For the choice: always choose the rating that matches the most severe condition that can occur in the relevant zone, not the average condition.
In environments with aggressive chemicals or corrosive fumes, additional requirements apply to the material of the luminaire housing. Stainless steel or specially coated aluminum housings are then necessary.
How do you calculate how many lighting points a production hall needs?
The number of required light points in a production hall is calculated based on the desired illuminance in lux, the area of the space, the mounting height of the luminaires, and the light output per luminaire in lumens. A professional lighting calculation using software such as DIALux or Relux provides the most reliable outcome.
The basic formula for a rough estimate works as follows:
- Determine the desired illuminance level on the work surface in lux (e.g., 300 lux for general production).
- Multiply the desired lux by the area of the hall in square meters. This will give you the total required luminous flux in lumens.
- Take into account a maintenance factor (typically 0.7 to 0.8) to compensate for the decline in light output over time.
- Divide the total required luminous flux by the lumen output of the chosen fixture. This gives the minimum number of fixtures.
- Check via a lighting calculation program if the distribution also provides sufficient uniformity over the entire floor area.
The mounting height has a great influence on the result. The higher the fixture is hung, the more lumens are needed to achieve the same lux on the work surface. For more background on how lumens and lux relate to each other, the page about luminous flux helpful explanation.
When is ATEX-certified lighting mandatory in a production hall?
ATEX-certified lighting is mandatory in zones where an explosive atmosphere may arise due to the presence of flammable gases, vapors, mists, or dust clouds. This is stipulated in the European ATEX Directive (2014/34/EU). The obligation applies as soon as a potentially explosive zone is designated in the risk assessment of the production environment.
ATEX zones are classified based on the frequency and duration of explosion hazards:
- Zone 0 / Zone 20: Explosive atmosphere is continuously or long-term present (gas or dust, respectively). The highest level of protection is required.
- Zone 1 / Zone 21: Explosive atmospheres can occasionally occur during normal operation. Luminaires must be certified for category 2.
- Zone 2 / Zone 22: Explosive atmospheres rarely occur and only for short durations. Category 3 luminaires are permitted here.
Typical production environments where ATEX lighting is mandatory include paint and lacquer factories, chemical production facilities, food companies with dust production (such as flour or sugar), and storage areas for flammable liquids. The zone classification must be determined by a certified expert and forms the basis for luminaire selection.
How JEL Products Helps You Choose the Right Lighting for Your Production Facility
JEL Products helps industrial organizations select, design, and implement the right LED lighting solution for production environments. This goes beyond simply supplying fixtures. JEL Products offers a comprehensive service, from lighting design and consultation to installation and commissioning.
What JEL Products specifically offers for factory lighting:
- Professional custom light calculations, tailored to the specific zones and requirements of your hall.
- Fixtures that meet the correct IP, IK, and ATEX classifications for your environment
- Solutions for extreme conditions, including high temperatures, corrosion, and vibration
- Guidance on subsidy and funding opportunities for energy-efficient lighting
- ISO9001 and VCA** certified execution of complete lighting projects
Would you like to know which LED lighting is best suited for your production hall? Get in touch Contact JEL Products for a no-obligation consultation.