Electricity + Control April 2018

LIGHTING

LED Lighting for Manufacturing: Save Costs While Improving Productivity Insights from the experts at Banner Engineering; supplied by RET Automation Controls

Saving money is an important consideration for most industrial users. Even if lighting does not account for a large share of the operating budget, every bit of savings can help the bottom line.

Take Note!

• Initial LED equipment costs for a lighting solu- tion is often more than competing technology options. Small improvements in efficacy can result in significant operating cost savings over the lifetime of a lighting solution. It is important to attempt to predict the lifetime of a given technology and understand how and when the lighting system will deteriorate.

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U pgrading lighting can be an effective way to reduce facility and machine costs while improving the productivity, safety, and functionality of a space. Costs of Ownership When considering lighting costs, industrial users should recognise that the initial cost of a light is only part of the life-cycle cost of the lighting solu- tion. Maintenance and lamp replacement costs de- pend on the lifetime of the equipment, and the en- ergy costs depend on the equipment’s efficiency. For this reason, longer-lasting and more-efficient technologies can produce significant savings, even if they are initially more expensive.

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Initial Costs of Lighting The initial equipment costs for a lighting solution include the housing, electrical equipment (e.g., the ballast or driver), and the light engine (e.g., the lamp or LED panel). LED equipment is often more expen- sive than competing technology options, and the difference can be significant for certain applications. Industrial users may also find that the initial cost of the lighting housing depends on the en- vironment. Some lighting can withstand the ex- treme conditions that are often present in industri- al environments. These safeguards may increase the cost of the equipment, but the risk of damage or injury to people or other materials in the space is reduced – ultimately saving costs long term. Different types of lighting upgrades require different investments in equipment. Lighting up- grades can be classified as retrofits or redesigns. Retrofits involve replacing the existing lights with more efficient technologies, while making use of the existing housing, lighting pattern, and elec- trical equipment. On the other hand, redesigns require new fixtures, modification of the existing lighting pattern, and partial or complete rewiring of the electrical system. Both retrofits and redesigns can involve up- grading to more efficient technologies, increasing or decreasing the total amount of illumination, and adding lighting controls. Both upgrade types can be simplified significantly by using fixtures with features like electrical cascading, integral wire connectors, and varied mounting options. Industrial users should consider a redesign of the lighting system if any of the following situa- tions apply: • The existing lighting solution is in poor condi- tion • The light distribution of the existing solution is uneven

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Figure 1: The costs of a lighting solution over a 15-year cycle, assuming typical costs, wattage, and lifetimes, for different technologies. Industrial users should calculate the lifetime costs of the specific equipment options they are considering before making a decision [1]. LED fixtures often have higher initial costs for a given application than other technologies; howev- er, they often are the most efficient option availa- ble and have the longest lifetime. Some industri- al users may find fluorescent or HID technology better suited to their needs, but that may not be the case for much longer given the rapid pace of advancements in LED technology.

28 Electricity + Control

APRIL 2018