Replacing Traditional Warehouse Lighting with LED Lamps

With the development of LED technology, replacing the traditional lamps with LED lamps is becoming more and more popular. Compared with the traditional light sources, there are many advantages of solid-state LED lighting: it is small in size and low in power consumption, its lifespan is long, it has high brightness while only generates small amounts of heat. It is environmentally friendly and very durable.

As a cold light source, LED lamps emit far less heat than conventional lighting. LEDs are completely encapsulated in epoxy which makes them much more durable than light bulbs or fluorescent tubes. The fact that LED emit far less heat than traditional lighting becomes particularly apparent in closed environments where it greatly reduces the risk of fire. To large warehouses, replacing with LED lamps not only will save the electricity fees by large degree, but also will offer a better lighting performance occasion with more safety.

Common Traditional Lighting Fixtures for Warehouse

Common traditional warehouse lighting fixtures include metal halide lamps, fluorescent lights and sodium lamps.

Metal Halide Lamps

Metal halide lamps are lamps that discharge gas at high pressure and are the most common type of warehouse lighting. Its light area is small, but it concentrates light rays, giving it long reach and light penetration. It is commonly used in bay lights or flood lights. Its disadvantage is that metal halide lamps with ballast are slow to start, and a require high starting currents, which effects the lifespan of the lamp. At the same time, the ballast consumes a lot of power and both increases the electricity costs of users and speeds up the aging of power lines. Additionally, its color rendering is rather poor, it emits ultraviolet radiation, and contains mercury which is harmful to the environment.

Fluorescent Lamps

T12, T10, T8 and T5 fluorescent lamps are also common types of warehouse lighting. They are usually installed in shelves. Compared with metal halide lamps under the same conditions, fluorescent lights consume half as much power. The warm-up time is even shorter, it has high luminous efficiency, good color, wide input voltage range, and is flicker free. But if fluorescent lights are frequently turned on and off the filament will quickly be blackened and soon broken. Fluorescent lamps have high mercury contents, and broken fluorescent pipes may cause serious damage to the environment. In addition, when fluorescent lamps are used in wet or corrosive environments, corrosion damage to components will negatively affect the lifespan of the lamp.

Sodium Lamps

Sodium lamps are another common type of warehouse lighting. When switched on, sodium lamps need to be warmed up, and if the power is cut they need to cool off and be re-heated in order to start. It can take up to ten minutes for this process to get achieve full power. Sodium lamps have big current harmonics and may emit piercing, unpleasant noises. Their color rendering capabilities and visual effects are poor, which affects worker productivity. The surface temperature of sodium lamps can be as high as 360 ℃. This can produce discomfort to people and turn into potential fire hazards.

Common Warehouse LED Lighting Fixtures

LED High Bay, LED Low Bay, LED T8 Fixtures, LED tri-proof lamps, LED flood light, are widely used LED lamps for warehouse lighting.

LED High Bay and Low Bay Light

Usually, LED bay lights that are installed at a height of 20 feet (6 meters) or above are called LED High Bay Lights, and those installed below that height are called LED Low Bay Lights. Bay lights are the most common types of warehouse lighting. Old-fashioned bay lights usually use 250W or 400W metal halide lamps, but those lamps generally only have an efficiency of 50lm/W and consume a lot of power. Because of this, recently constructed warehouses use LED lamps as a new generation of light sources, and a large number of existing traditional bay lighting is undergoing energy-saving upgrades and is slowly being replaced by LED Bay lighting.

warehouse lighting with led high bay lights

LED T8 Fixtures

LED T8 tube lighting is the ideal choice when replacing traditional fluorescent lamps. In comparison, the LED T8 has the following advantages:

Light efficiency: fluorescent tubes emit light in 360 degrees. The light which is diffracted through the lampshade may be blocked or absorbed, which decreases the lamp’s efficiency. Because of this, fluorescent tubes usually use white lampshades, which can reflect light back and increase its usefulness. In general, fluorescent tube lights only have an efficiency of about 70%. LED tubes, on the other hand, emit light in 120 degrees, so almost all of the emitted light is projected towards the area that needs to be illuminated. Add to this the inherent efficiency of Solid State Lighting (SSL) which allows LED T8 to consume less than half as much power as fluorescent tubes.

Safer: High quality T8 LED equipment features reliable insulation design, and thanks to components supplied by well-known brands, power supply drivers have high tolerance. Internal components do not create heat, and because the electrical currents generated by LED drivers are so low, the wires themselves do not produce any excess heat either. Because of this the fire hazard is much lower compared to traditional fluorescent tubes.

Ease of replacement: When replacing a traditional T8 light, one has to remove the driver first. An LED T8 can be directly installed and immediately put to use. This saves labor and maintenance costs.

warehouse lighting with t8 led tube

LED Tri-proof Lights

LED tri-proof lamps are lamps that are waterproof, dustproof, and corrosion resistant. A lamp which is non-permeable and without holes can keep water and dust out. Lamps often have some amount of surface treatment (anti-corrosive coating, anodizing etc.) to increase the anti-corrosive properties of the lamp material. Corrosion-resistant plastic or glass is used as optical material, and together with silicone seals and rust-free screws the lamp is sufficiently protected.

LED tri-proof lights use an integrated streamlined structure, producing uniform soft light, without glare or overlapping shadows and effectively reducing discomfort and fatigue among warehouse staff. The inside components are vibration resistant and can sustain frequent long term vibrations. The shell protection grade is IP65 and corrosion protection grade WF2. This means that the shell never corrodes and never rusts.

Tri-proof lights also have good electromagnetic compatibility, and are not likely to be affected by surrounding electromagnetic interference. The tri-proof light is a combination of clean, energy-efficient, and long-lasting technology. It can certainly be said that LED is the best choice for warehouse lighting.

LED Flood Light

LED flood lights spread light evenly in every direction, and the exposure range can be freely adjusted. Most LED flood lights have symmetrical light distribution, which is often manifested in a symmetric polygon or circular shape. Since the light exposure area of flood lights is rather big, their light is easier to control. There are many secondary uses for them. They can for example be positioned very close to the object they are intended to illuminate in order to make it appear extra bright. In parts of the warehouse where even light distribution is desirable (e.g. by test or inspection desks) LED lights are ideal.

Low Cost Warehouse LED Lighting Ideas

Economy Lighting Solution #1: Uses our high-powered E40 light bulb to replace more expensive LED bay lights, retaining the original lamp shade. This direct replacement is one time only, very convenient and saves effort. One can also choose to use simple LED T8 fixtures to replace LED tri-proof lights, which is useful when the lighting requirements are not as high and one wants to reduce one-time investments.

Economy Lighting Solution #2: Uses dual or multi-channel lighting during peak operation hours, and single channel lighting during low operation hours.

Economy Lighting Solution #3: Uses PIR motion sensor control, which activates lights automatically when it detects people, and turns itself off after they have left. Another alternative is a microwave sensor with time control which intelligently adjusts lighting to suit the flow of goods and people in a given area. This reduces unnecessary waste of power.

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