Benefits of Customized LED Lighting in Production Lines

Production line illuminated by LED iBond lights at Ball Beverage Packaging

Having a smart lighting approach on production lines can increase productivity and lower operational costs. Over the years, manufacturers have realized the brilliance of LED lights for business, which includes their energy efficiency, low replacement rates, low heat output, and high quality of lighting. All of these contribute to a better fulfillment of both production and employee needs, higher operational efficiency, and lower operational costs in the long term. For manufacturers looking for an upgrade for their factory floors, integrating LEDs in their production line lighting is a must. Below, we take a look at the four major benefits in detail.


Lower Operational Costs in the Long-Term

As the industry is making strides towards eco-consciousness, LEDs, in the first place, have become a popular choice on production lines. Despite a slightly heftier price tag upon first glance, compared to traditional lighting solutions such as incandescent and fluorescent bulbs, LEDs consume much less energy.

To produce the same brightness level, the average LED bulb uses 6 times less energy than the average incandescent bulb and nearly 1.5 times less energy than the average fluorescent bulb. This is based on comparisons of lumens per Watt, which measures the amount of brightness put out by each type of bulb consuming the same amount of power. This low energy consumption will lower electricity bills in the long run.

Additionally, LEDs are efficient at using the energy they consume, and they have long service lives. Lasting for up to 50,000 hours, LED bulbs can be used continuously for up to 6 years before any need for replacement. In fact, with our own patented sandwich system here at LED iBond, we offer LEDs with up to 100,000 hours of service life. This is double those on the market. Our LEDs can be used for over a decade without replacement, saving on replacement costs and preventing production from being halted due to operational interruptions.

To maximize the potential of LEDs, we have also created Everly, our superior bulb replacement concept customized for our lighting solutions. With Everly, bulb replacements take mere seconds, and there is no need for manufacturers to replace the entire lighting fixture every time a bulb burns out. Everly is also durable, which is an added benefit for its use on production lines.

Factory floors of medium to large sizes typically employ hundreds of bulbs at one time. With the use of energy-efficient lighting solutions such as the LED, less power is consumed, and there is greater longevity of each bulb. Even when they have to be replaced eventually, it can be done quickly. This saves a considerable amount of time, energy, and money – a triple win for all manufacturers with busy production lines.


Better Fulfillment of Production Needs

Customized LED lighting also makes great production line lighting due to their availability in different tonal shades of white, such as warm, neutral, and cool. These tones are measured by a Correlated Color Template (CCT), which indicates the color appearance of the white LEDs. Measured in degrees Kelvin, warm light is around 2,700K, a neutral white at around 4,000K, and a cool white from 5,000K and higher. These tones can be picked and combined to create a production line that is perfectly suited for its operations.

Previously, LED iBond has had experience aiding Ball Beverage Packaging in their lighting design across the factory floor. The aluminum can manufacturer has automated production that runs 24 hours a day on all 365 days in the year, producing 120 aluminum cans per second. Focusing on the production of the cans and quality assurance, they required personalized LED lights on its inspection lines and factory ceilings.

For the project, LED iBond created specially adapted LED panels and luminaires to fulfill the manufacturer’s needs. We chose neutral and cool white LED bulbs with CCTs between 4,000 and 6,500K to be installed in robust luminaire fixtures so they can not only provide high quality lighting but also be well-protected against breakage from accidents. We also ensured that our LED bulbs provided a brightness that did not diminish or degenerate over time, as well as a Color Rendering Index (CRI) above 90, to meet the project objectives.

Color Rendering Index (CRI) measures a light source’s ability to reveal the true colors of the various objects they shine on. On a scale of 1 to 100, a CRI of around 80 is the general acceptable standard for color rendering in indoor spaces. However, on factory floors where quality assurance of products’ color compositions is concerned, a CRI of at least 90 is required. This makes LED technology efficient production line lighting.


Better Fulfillment of Employee Needs

To begin with, LEDs can make going to work comfortable for employees as they produce little heat even after hours of operation. This is due to its technology. Unlike traditional lighting solutions which have wire filaments that are heated to generate light, light-emitting diodes are solid-state devices, meaning it uses a solid semiconductor material that converts electricity into light without excessive heat. This also means that traditional lighting solutions, when in operation for a long time, will be extremely hot to touch compared to LEDs.

Keeping temperatures low on the factory floor is crucial for production lines that operate on a large scale. As they are often equipped with more than hundreds of light bulbs, tubes, and panels, choosing the wrong type of lighting can cause an overheating of the working environment, making it extremely unpleasant for employees. The hot surfaces of traditional bulbs will also pose a safety hazard for employees working on cramped production lines.

To keep workers safe and happy, we always recommend a customized approach for production line lighting. Our previously mentioned patented sandwich system is designed to boost heat management through holding both high and low voltage LED lights between two Aluminum Composite Panels (ACPs). Aluminum, an excellent thermal conductor, helps to dissipate any heat generated, and as the panel is ultra-slim at only 6mm, it also strives to prevent overheating. As our panels are wireless, it also minimizes safety risks for employees, such as the tripping over of wires or their entangling.

The use of our LED panels can be further customized. Different combinations of LED lights can be installed along production lines to make it easy to tweak brightness levels and tonal shades to suit employee needs. For example, panels installed at the assembling section of a production line can contain cool white LEDs to help employees stay alert and on task, while panels installed at the packaging section of a production line can host neutral white LEDs with a high color rendering accuracy for employees to perform quality assurance of the materials.


Higher Overall Operational Efficiency

The use of customized LED lights can also maximize overall operational efficiency on production lines. This is through the combination of LED light fixtures with external technology. A pioneer of lighting design, here at LED iBond we provide supplementary lighting solutions that are equipped with full Internet of Things (IoT) integration. This means that our fixtures for energy-saving LED lights, such as shelves and panels, are compatible with modern technology for both indoor and outdoor spaces.

This IoT integration can be done with various hardware and software, such as motion, light, spatial, and sound sensors. This means that parts of production lines can become fully automated, and human employees can be delegated less monotonous tasks. Good manufacturers know where on production lines to utilize human ingenuity and where to utilize technological efficiency. Great manufacturers know that these two can be combined, and their joint effort can achieve much more.

Should workers also want to collect data on their production rates after full or partial automation, this can also be done with our customized LED lights. Data collected can be stored, exchanged, and accessed on various devices to monitor productivity.

For longer production lines, our customized LED lighting fixtures can also work within Building Management Systems (BMS) thanks to open platform technology. This means lighting panels can be hooked up to heaters, speakers, and ventilation and security systems, as well as other fixtures across the entire factory floor. With the system, everything can be controlled on a single device, and easily, too. Dimmable LED lights can be dimmed with the touch of a finger, and bulbs can be turned on and off remotely. This accessibility can increase operational efficiency by saving time and manual effort.


Get in Touch

With customized LED lighting on production lines, the possibilities for innovation are boundless. Keep employees happy and allow production rates to soar with our very own patented technology here at LED iBond. We understand industrial lighting challenges and seek to provide assistance in creating the optimal working environment across the industry.

For more information, please contact Sales on the button below. We look forward to talking to you.