When Is It Time to Upgrade Industrial Lighting?
Lighting in industrial and demanding working environments is exposed to considerable wear and tear every day. Over time, luminaires deteriorate, light output decreases, and energy consumption can increase unnoticed. Outdated lighting is not just a cost issue since it directly impacts workplace safety, working conditions, and productivity.
When your lighting system no longer meets the needs of the space or the work being carried out, it is time to consider an upgrade. The following signs can help you identify if the industrial lighting system is due for renewal.
Signs That It May Be Time to Upgrade Your Industrial Lighting
- Luminaires are damaged or brittle.
- Energy consumption has increased.
- The lighting no longer meets the needs of the working environment.
- Lamps or spare parts are no longer available.
- Reduced light output makes work more difficult.
- Lighting failures cause production interruptions or unexpected risks.
- Lighting requires too much maintenance.
1. Damaged or Deteriorating Luminaires
Industrial luminaires are continuously exposed to moisture, dust, chemicals, temperature changes, and mechanical stress. Plastic-bodied luminaires can become brittle, crack, or corrode over time, reducing their protective properties. Challenging environments include damp spaces, industrial facilities exposed to chemicals, and agricultural buildings such as barns.
Deteriorated luminaires should be replaced since they no longer meet the specified IP ratings, and compromised enclosures are an electrical safety risk.
For demanding environments, we recommend LED luminaires with aluminium or stainless-steel housings. They offer significantly better resistance to corrosion, chemicals, and mechanical stress.
Explore Tehdasvalo's LED industrial luminaires
2. Increased Energy Consumption
Older lighting technologies consume considerably more energy than modern LED solutions. In particular, the light output of discharge lamps and fluorescent luminaires (lm/W) decreases over their service life, while energy consumption remains high or may even increase.
Switching to modern LED lighting can reduce energy consumption by 40–60%. When combined with smart lighting controls, such as motion or presence detection and daylight harvesting, the savings can be even greater.
Lower energy consumption directly reduces operating costs, cuts environmental impact, and supports a company's energy-efficiency targets.
3. The Lighting No Longer Meets the Needs of the Working Environment
The requirements of a working environment can change as production processes and tasks evolve. If the lighting cannot be adjusted to suit different work areas or levels of use, both working conditions and energy efficiency can suffer.
In many older systems, lights operate at full power even when areas are unoccupied or full illumination is not required. Area-based controls, dimming, and automatic lighting adjustment may be missing, meaning that the lighting system is no longer suited to the actual needs of the working environment.
Modern lighting solutions offer effective control options that allow lighting to adapt to different situations and tasks. The result is better working conditions, lower energy consumption, and a longer service life for the luminaires.
4. Lamps and Spare Parts Are No Longer Available
The production of lamps and spare parts for many discharge and fluorescent luminaires has been discontinued due to EU energy-efficiency requirements and changes in manufacturers' product ranges.
If lamps, control gear, or other spare parts are no longer available for your existing luminaires, this is a clear sign that it is time to consider an upgrade. LED technology provides a long-lasting and future-proof alternative.
5. Reduced Lighting Output Makes Work More Difficult
Insufficient or uneven lighting can reduce work quality, slow down processes, and increase the risk of errors and workplace accidents. Good lighting is particularly important for tasks that require precision and attention to detail.
The lighting requirements for different work environments are defined in the SFS-EN 12464-1 standard, which specifies target values for factors such as illuminance (lux), uniformity and glare (UGR). If these requirements are no longer met, the lighting system is no longer providing suitable conditions for the working environment.
Light output also decreases as luminaires and lamps age.
- The luminous flux of metal halide lamps decreases over their service life and can be as low as half of the original output towards the end of their life cycle.
- High-pressure sodium and fluorescent lamps maintain their light output better, but their energy efficiency decreases as they age.
- The economical service life of discharge lamps is typically around 3–3.5 years, after which their energy efficiency and lighting performance can deteriorate significantly.
Some modern LED luminaires use Constant Light Output (CLO) technology to compensate for the gradual decrease in luminous flux over time. First, the luminaire operates at a lower power level that increases over time. This compensates for the natural depreciation of light output and keeps illumination levels consistent throughout the planned service life.
Well-designed lighting improves safety, supports productivity, and helps reduce human error.
6. Lighting Causes Production Interruptions
Ageing luminaires, control gear, and lamps can fail unexpectedly or interrupt production, causing delays or safety risks during critical operations.
LED lighting significantly reduces the risk of failures thanks to its long service life. At the same time, maintenance requirements are reduced, improving production continuity and reliability.
7. Lighting Requires Too Much Maintenance
If the lighting system requires frequent maintenance and repeated urgent repairs, replacing the entire system is often the most cost-effective solution in the long run.
Maintenance work can cause production delays, while unexpected lighting failures place additional pressure on maintenance teams, as repairs often have to be carried out urgently.
Maintenance costs are high in elevated production and storage facilities, where replacing luminaires may require lifting equipment or production shutdowns. In addition, the costs can be even higher in hazardous areas, cleanrooms, and other special environments.
Modern, reliable LED luminaires reduce the need for maintenance, lower operating and maintenance costs, and free up valuable maintenance resources for more important tasks.
Upgrading an Existing Lighting System
Modernising your lighting does not always mean replacing the entire system. In many facilities, existing luminaire housings and cabling can be retained while the lighting is upgraded to modern LED technology.
The experts at Tehdasvalo can assess the condition of your existing lighting system and help you find the technically and economically optimal solution for your facility.
Contact our experts; let's design a safer, more energy-efficient, and longer-lasting lighting solution for your facility.
