Industrial LED Stack Lights Applications in Manufacturing

In manufacturing sites, LED stack lights promote safety and provide real-time notifications (when equipped with an audible horn) of specific activities or dangers in the area. The unit’s versatile options and compact design makes them ideal for installations over heavy machines, as well as in elevated positions.

Outside of manufacturing, LED stack lights can be found in maintenance call stations, broadcast studios and CNC machining (just to name a few).

Color Codes and LED Stack Lights

LED stack lights typically come in various color combinations and selections, based on the type of signaling required by the business. At a basic level, green LEDs are applied to signal ongoing operations, while red LED work lights are used for emergencies, suggesting operations should be stopped.

For special requests, such as maintenance or scheduling, a blue LED is deployed. It is important to consider that, in application, businesses may choose their own set of colors and applications for signaling. When setup properly, the units can improve productivity.

Audio Signaling and Other Features

These days, industrial LED stack lights are being combined with other signaling devices, including loud horns. This adds another layer of notification, ensuring those who are visually occupied with a task can still receive notifications clearly. LED stack lights with audio horns are commonly utilized for traffic signaling systems in warehouses and industrial sites.

Machines can also be wired into the LED lighting system, so that a human operator does not need to manually activate the unit. As a result, signaling is faster and more reliable.

LED stack lights can be designed to suit specific work environments. Explosion proof variants are for locations that handle or are exposed to flammable elements. For food manufacturing facilities, waterproof and corrosion-resistant options are recommended in order to withstand persistent water spray or harsh cleaning chemicals during washdown sessions.…

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Understanding Tunnel Lighting Zones and Configurations

Tunnel lighting systems are configured and installed, based on five zones: Access Zone, Threshold Zone, Transition Zone, Interior Zone and Exit Zone.

Read on to learn about the industrial lighting requirements of tunnels and how to calculate tunnel lighting for each

Access Zone

This area is located outside of the tunnel, specifically the strip of road that leads to the tunnel’s initial entry point. The primary role of lamps in the access zone is enhanced clarity. The lights should allow individuals entering the tunnel to adjust to the conditions of the area. Access zone lighting configurations are considered successful when a driver can enter the tunnel without decreasing speed.

Threshold and Transition Zones

Threshold and transition zones gradually adjust lighting conditions to cater to the dimly lit nature of tunnels. By slowly reducing illumination, drivers are less prone to developing ‘blind spots’ created by rapidly switching exposure between daylight conditions and dark tunnels.

Ideally, the end of the transition zone should provide up to three times more illumination, compared to the interior zone.

Interior and Exit Zones

As the term suggests, the interior zone is the deepest part of the tunnel. In most cases, the amount of illumination required is dictated by the type of activity inside the location. For road-related activities and traffic, traveling speeds and density must be taken into consideration.

Lastly, the exit zone provides the required illumination for safe travels leading out of the area. Interestingly, the visual principles applied in the access, threshold and transition zones are not needed in the exit zone. This is because humans can easily adjust between dim and bright lighting levels easier, compared to adapting from bright to low lighting conditions.

To guide drivers out of the tunnel, lights in this zone are installed to provide contrasting conditions, in the event the exit point (and surrounding signs) is obstructed or hard to identify.…

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LEDs Are not Cheap: Here’s How to Get the Most for Your Money

Led spotlights are no more a no-brainer.So here’s your technique for buying. The inefficient lamp phaseout has started, and CFLs are not your only option. There’s another mainstream option: LEDs if you are ready to pay the price.

Buy LEDs slowly but surely as time passes.

With the average household’s about 40 sockets, that is $800-$1,600 in led spotlights. However, prices will drop given that the inefficient incandescent is restricted and competition rises among LED manufacturers. How fast they willdrop is a topic of theissue — some experts project a 50% price is lowering over another five years, but others think we will see a 75% cut down by the end of 2012.

Buyled spotlights when the purchase price drops below three times that of an equivalent CFL given that they last 3 x as long. For instance, CFL reflector lights — the flat-topped lights you put in floodlights or recessed fittings — typically cost around $10, so look for prices below $30 for similar LEDs. “In Vermont, where I live, I came across LED retrofits for recessed fittings for $20,” says Russ Leslie, associate director of the unbiased Lighting Research Center in Troy, N.Y. “It was a no-brainer.”

We did the math on the payback for swapping incandescents with LEDs.

Keep in mind that these numbers derive from national averages, which means that your results will vary:

Assuming lighting makes up about 6% (or even higher, depending on which national source you seek advice from) of the average $2,200 gross annual energy bill, according to the U.S. Section of Energy, and LEDs are 75% more efficient than incandescents, you’d save about $100 per season by transitioning totally to LEDs.

Combine sales prices you will probably find with rebates from your state or your utilityfor personal savings, says Leslie. The Databases of State Incentives for Renewables & Efficiency can help.

Replace high-wattage and frequently used incandescent lights with LEDs in:

  • Recessed (can) light. These tend to maintain places where use is high, such as kitchens, which account for the most kilowatt time per season in American homes, based on the Lighting Research Centre. “LED retrofits for recessed light are ready for theprimary time,” Leslie says, “and CFLs in that application are not nearly as good.”
  • Open fixtures. Concentrate on drop-bowl light accessories, lamps, and other accessories where air can circulate readily around the light bulb. LEDs, like CFLs, don’t perform as well in enclosed fittings where heat builds up.
  • Outdoor Lamps. The high wattage of outdoor floodlights makes them a good replacement concentrate on. LED floodlights are improving technology and will likely become cheaper this season, Leslie says, so you may want to put off this purchase until later in 2012.

Problems with led spotlights

Hold off on replacing lights in enclosed accessories, as they tend to burn out faster. More domestic fixtures designed for LEDs begins hitting the marketplace this year, Leslie says, which should address a few of the problems led spotlights to have with high-temperature conditions. As the quality of LEDs ranges widely, be certain to choose one with the power Star label.

Your final thought: Suzanne Shelton, CEO of Shelton Group and an expert on consumer behavior toward energy efficiency, recommends that you start thinking about your lights as an investment. “Save the boxes from your LEDs and take them to you when you move,” she says.

What’s your lamp strategy? Do you use a combo of led spotlights and CFLs, or hoard incandescents while certain wattages remain available?…

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Benefits of High CRI Lighting in Industrial Facilities

In industrial buildings, work lights are capable of enhancing clarity over the work space. Specifically, brightness ratings are used to gauge the distance of light beams and detection rates. Another factor that is rarely considered, when selecting lights for industrial work sites is color rendering index (CRI) values. This refers to the unit’s ability to reproduce certain colors with a high degree of accurateness, resulting in robust color depiction. Read on to learn about CRI lighting and its applications.

Measuring the Quality of Illumination

CRI ratings are applied, based on a 1-100 scoring system. The rating is measured using eight standard pastel colors, which are averaged together to arrive at the CRI value.

Most LED lamps come with a CRI rating of 80+. While fluorescent fixtures provide CRI ratings between 62 and 90 (or higher). Interestingly, out of all the lighting technologies available in the market today, mercury-vapor units offer the lowest CRI ratings, at roughly 45. CRI values in the 90+ range are considered optimal for design or color-related applications.

It is important to consider that CRI values cannot be used to determine the characteristics of the light on its own. Other factors, such as color temperature and beam angle, can also affect color depiction.

For instance, low color-temperature units provide yellowish to reddish illumination, which results in less accurate color rendering. To better understand this, imagine the way objects look during sunset, compared to the way objects appear during mid-afternoon.

Applications for High CRI Lighting Systems

High CRI light sources, such as LEDs, are useful in a variety of locations and work sites. Examples of tasks, sectors and services that can directly benefit from this type of luminary include the following: commercial paint spray booths, art shows, photo galleries, large-scale exhibits, laboratories, scientific testing, manufacturing floors, design rooms and more.…

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How to Address Vibration When Using Industrial Work Lights

Outdoor work sites, such as construction, logging, mining, agricultural operations and mineral processing, experience large amounts of vibration. Over time, such elements can hinder and destroy work lights lighting systems.

Read on to learn how to address vibration experienced by lights in rugged environments.

Reducing Vibration and Premature Failure

There are several ways to decrease the negative effects of vibration on lights and other equipment at the site. One of the most effective and low-cost methods involves the installation of sturdy mounting components. For example, a U-bracket mount for an LED light bar may decrease unnecessary shaking, when secured on a tractor or ATV.

Furthermore, a thick pad can be installed at the base of the mount (at the surface) to absorb heavy vibrations. For long-term maintenance, operators in work sites that experience constant vibration should inspect their work lights lighting systems to ensure the parts are still intact and working properly.

Types of Vibration

There are three main types of vibration that occur around heavy-duty equipment and industrial work sites. The first, called harmonic vibration, originates from large machines. This type of disturbance deals with external vibrations, which can be reduced by using a shield to block or absorb incoming harmonic waves.

Arrhythmic vibration occurs when operators expose a device or equipment to damaging forces. This is usually done randomly, such as navigating over a road filled with potholes or carrying a portable light up a ladder, causing the luminary shake and hit objects on the way up. Arrhythmic vibration is dangerous because it can contribute to breakage.

Lastly, rhythmic vibration is constant vibration stemming from nearby machines or large sources. For instance, an outdoor spotlight next to an industrial water pump may experience this type of vibration while it is operational. Unlike arrhythmic vibration, this type of constant and contributes to damage over a long period of time.…

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What Are SMD LEDs for Industrial Work Lights

LED modules come in different shapes and sizes. Initially, the first design incorporated a bullet-like shape, which is currently a representation of what most people think of when referring to LED  work lights.

Called DIP LEDs, the design was eventually superseded (but still commonly found today in mainstream electronics) with new LED modules with improved performance. Very suitable for industrial lighting systems, Surface Mounted Diode (SMD) LEDs offer a myriad of benefits, in terms of lifespan, thermal dissipation and performance.

SMD LEDs 101

In an SMD LED module, the chip is directly installed on the PCB (secured on an aluminum substrate). This results in a flatter, more versatile design. Due to the change in shape, the characteristics of a light beam from an SMD LED module also changes. Typically, light coming from an SMD LED source is wide, in the range of 120 degrees – or flood. Without an encapsulated cover found on DIP LEDs, the focus of the beam lacks direction.

When it comes to performance, the units consume up to 20 percent less energy during operation. Furthermore, due to the LED module’s ability to mitigate heat, SMD LEDs feature lengthy lifespans, capable of exceeding 50,000+ hours under optimal conditions.

Industrial Lights and SMD LEDs

Compared to DIP LEDs, SMD LEDs provide increased lumen output in a significantly compact size, making the modules ideal for industrial lighting systems. Furthermore, such physical characteristics are advantageous for businesses looking to take on retrofit projects, transitioning from fluorescent or incandescent fixtures to energy-efficient LEDs.

SMD LED work lights are capable of catering to different lighting color combinations. Lastly, since fixtures that utilize SMD LED modules offer brighter lumen output, less lights are needed in the target area. This is extremely beneficial for tight spaces, such as tanks, storage rooms and control centers, with limited room to move around.

If you are looking for led work lights, please visit where you find a great selection of US Made lighting fixtures for your application.


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Benefits of Full-spectrum Lighting for Commercial Livestock and Birds

What is Full-spectrum Lighting

Like humans, animals are sensitive to natural light cycles. Because of this, businesses that specialize in raising livestock, such as chickens and turkeys, must utilize lamps that offer similar advantages associated with sunlight.

By comparison, many bird pet owners like to use low quality compact-fluorescent bulbs inside bird cages at home. This practice is not recommended, as the lamps are too bright for tight spaces. Over exposure to extremely bright artificial light for extended periods of time can cause birds to become uneasy and anxious.

Full-spectrum Lighting for Birds

In commercial livestock operations, full-spectrum lighting provides numerous physical benefits for animals. The lamps offer a range of ultraviolet bands that can also be found in the natural habitat of birds and other creatures.

In particular, birds rely on UVA bands for image and food recognition. Humans can’t see UVA wavelengths, as we do not have the same set of cones inside our eyes to facilitate the activity.

Moving on to UVB, this range provides vitamin D for birds. When the animals preen the feathers on their bodies, precursors convert the compounds (from light) to vitamin D3.

Failure to provide birds with proper full-spectrum lighting could result in the following: bone-related medical conditions, plucking of feathers, seizures and issues with reproductive patterns. On the other hand, too much full-spectrum lighting can also be harmful to birds and reptiles.

Exposure Requirements

Overall, the main goal of full-spectrum illumination for birds is to closely resemble sunlight. Birds are normally exposed to an estimated 12 hours of daylight and 12 hours of darkness in their natural environment. Changing this rate can cause some animals to develop differently because it triggers a seasonal change in their environment. For example, changing the period of light exposure could initiate a shift in sleeping behavior, breeding and migration.







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How Aircraft Hangars Benefit From High Bay LEDs

Industrial aircraft hangars are colossal buildings that host a menu of maintenance and repair services for planes. These establishments require elevated illumination, in the form of high bay leds lighting systems. Mounted roughly 16-50 feet in the air, the units could be secured on the ceiling, which allows the lights to either be fixed on the surface or hang freely with suspension brackets.

Aircraft hangars worldwide are switching to LEDs, due to their energy efficient and robust illuminative properties. This article focuses on the completion of a leading airline’s project in transitioning from metal halide high bay lamps to LED high bay units.

Addressing Lumen Depreciation and Re-lamping

The H1 Hangar is designed to facilitate three aircrafts in real-time. With over 120 planes in the operational fleet, it’s common for the hangar to require 24/7 support from industrial work lights. For illumination, operators and engineers working in the space rely on 226, 450-watt metal halide high bay fixtures. The units are mounted roughly 82 feet from the ground.

In addition to costly maintenance associated with the outdated lighting system, they also did not provide enough illumination for special tasks that called for 400-450 lux (the metal halide high bay lamps were only capable of offering 200 lux during operation). Re-lamping tasks were also difficult to execute, due to the presence of large aircrafts.

High Bay LEDs Lighting System for Aircraft Hangars

After switching over to high bay LED fixtures, the aircraft hangar improved productivity, illuminative accuracy and safety. The units offer up to 125 percent more illumination, which actively meets the requirements of 400-450 lux and 60-80 CRI for aircraft maintenance tasks. At full capacity, the lighting system consumes up to 45 percent less energy than the previous metal halide lamps.

To improve energy consumption, operators installed a control system that manages usage based on occupancy inside the location. This component increased the site’s savings by an additional 40 percent.…

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Everything You Need to Know About LED Light Bulbs

The invention and the use of Led lighting or the Light Emitting Diode bulbs are considered a major breakthrough in the history of mankind. It is one among the best innovations mankind has ever witnessed. Known for its innumerable advantages, these bulbs are used to light residential properties as well as commercial centers.


Some Interesting Facts


With the rise in energy costs, markets are flooded with alternative products which serve better and more efficiently. The invention of the LED light bulbs is one among such innovative products known to reduce soaring electric bills. This bulb is actually a collection of individual bulbs of different wave lengths producing white light.


The light from these bulbs are emitted from a solid object which is otherwise known as SSL or Solid State Lighting rather than a gas or vacuum.


The Led lighting can be easily installed as it is compatible with most of the electrical units. These bulbs are used for decorating homes during functions and festivals. Moreover, these bulbs are available in different shapes including rope lights, Christmas trees, garlands and so forth.


What Are The Basic Advantages of Using Led lighting?


The increase in the use of these bulbs can be attributed to a number of facts which are mentioned below:


  • Higher efficiency: Compared to the ordinary incandescent bulbs, the LED light bulbs are more efficient and effective. In addition, it saves energy as it requires considerably less amount of power to heat up.


  • Lesser heat: These bulbs produce negligible amount of heat and it can be used for the growth of indoor plants. The bulbs are also cool to touch even when lit.


  • Environment friendly: The Led lighting are known to be eco-friendly as it does not emit any kind of toxic fumes while burning. It seldom shatters or breaks; it does not pollute the environment either.


  • Durable and tensile: Compared to the other light bulbs, these bulbs are long lasting and durable. It seldom requires replacement as it does not break easily. Unlike the fluorescent bulbs, these bulbs are strong and compact in size.


  • Resistance: The bulbs are also resistant to cold, shock and heat. It can be used for wide number of applications.


Unlike the incandescent bulbs, these bulbs are not manufactured with the use of mercury and so it is considered safe for users and manufacturers. It seldom poses any kind of health and environmental threats. Flash lights which use Led Lightning tend to have a longer battery life as it utilizes minimum amount of power.


Another notable advantage of using these bulbs include the fact that it takes only seconds to light up after it is switched on unlike the incandescent bulbs and tubes. The LED light bulbs are available in different colors such as white, red, blue, green, and yellow.


The Ledlighting are also used in remotes, calculators as it is compact in size. It is also used for traffic lights as it is quite economical. These unique varieties of bulbs can be bought easily from many of the leading online stores.


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DIP vs COB Lights – What is the difference

LEDs are not all created alike. Some models contain very distinct, individual diodes – of which resembles most people’s thoughts about LED lighting. On the other hand, newer variants take on flat shapes, closely resembling a computer chip board.

If you’ve encountered such choices, you’re not alone. Generally speaking, there is a broad range of LED designs available in the market today, such as the following: Dual In-line Package (DIP), Surface Mounted Device (SMD) chips, Chip On Board (COB Lights) and Multiple Chip On Board (MCOB).

DIP LEDs and Traditional Lighting

DIP is one of the first designs to reach industrial and commercial markets. Consisting of the iconic “bullet” design, this type of LED is easily distinguishable by its shape and two long contacts that stick out at the bottom of the diode. This component is typically soldered on a board, when incorporated with other devices.

The low-cost units offer bright illumination and can fit inside compact spaces, making them suitable for flashlights, toys, controllers and warning systems. These days, traffic lights, construction signs and outdoor advertising boards utilize DIP LEDs. During operation, each diode produces roughly 3-4 lumens, while pulling around 0.05 watts.

Advantages of COB Lights

COB is a modern chip configuration that crams up to 9 or more diodes per chip. Unlike DIP LEDs, this variant takes on a condensed chip design and leverages one circuit and two contacts – regardless the number of diodes. Industrial facilities with large lumen requirements can benefit from COB LEDs, with light beams shining in all directions. Lumens-per-watt ratios are also maximized, capable of reaching between 80 to 100 lumens per watt.

Additionally, they can withstand extreme temperatures, resulting in persistent illumination and increased productivity during work in industrial sites. From a manufacturing perspective, SMD LEDs, which are predecessors of COB LEDs, cost up to five percent more to produce.…

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