Lighting Design and Simulation

Lecture 14. Lighting for Industry and Trade

TDMU
Lecture overview
• Good lighting
• Lighting concepts
• Optimal lighting
• Industry lighting
• Metal processing • Food processing
• Automobile workshop • Textile industry
• Electrical and electronic • Wood working
industry • Storage and logistics
• Printing
• Chemical industry
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Lighting and productivity
• Good lighting of the workplace means
higher productivity, better quality and
better safety.
• To produce good products, good tools,
good machines, good workers and
good lighting are needed.
• Only good lighting allows the proper
use of vision, which is required in
today’s manufacturing processes.

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Good lighting motivates
• Light not only allows the use of
vision but also has non-visual
effects.
• Poor lighting is like bad weather.
We are in a bad mood and
therefore we work worse.
• With good lighting we feel better,
we are in a good mood and we
work easier and better.

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Bad lighting is tiring
• The use of vision in normal conditions consumes
about 25% of the energy needed by the nervous
system to function.
• Under poor visual conditions, energy consumption
increases, causing fatigue to occur earlier.

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Good lighting is a profitable
investment
• Investments are necessary to
maintain competitiveness.
• The investment is expected to
reduce costs, increase
productivity and improve
quality.
• Good lighting does just that: it
reduces costs, increases
productivity, and improves
quality.

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What is a good lighting
• Lighting must be adapted to
the space and work or visible
tasks.
• The shape and height of the
room determine what light
sources should be used.
• The type of work (visual task)
determines what kind of
lighting concept should be
used.

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Choice of light source
• LEDs, fluorescent lamps and compact
fluorescent lamps are used for places
with heights up to 4 m.
• For higher places, LEDs with lenses
and (compact) fluorescent lamps
with suitable luminaires with
(narrow-beam) reflector can be used.
• For very high spaces, mirror reflector
luminaires with HID lamps of higher
power or special LED luminaires are
a proper choice.

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Lighting concepts
• General lighting provides the same visible
conditions throughout the place.
• The distribution of workplaces can be arbitrary. The
place usually works positively. It is especially
desirable
in larger rooms.

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Lighting concepts
• Localized (area) lighting is oriented to (fixed)
workplaces that are better (differently) lit than the
rest of the place.
• It allows different illuminances in different
workplaces. Electricity
consumption is
reduced. However, the
illuminance uniformity
in the place is not so
good.

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Lighting concepts
• Local lighting illuminates only (limited area of) the
workplace.
• It is used mainly where we want to achieve special
conditions in (one) workplace: high luminance, high
shading, a certain
direction of light, ...

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Standards
• Requirements for workplace lighting are given in
the standard ISO 8995 - 1 and -2.
• The requirements in the standard are the minimum
requirements that lighting must meet.
• Instead of „minimal“ lighting, it is better to provide
an optimal one that is adapted to the workplace
and work and so allows higher productivity, less
fatigue, fewer errors and fewer injuries at work.

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Optimal lighting
• Higher illuminance usually results in higher
productivity.
• The effect is greater in workplaces where workers
face more difficult
visual tasks.
Increase in output [%]

Illuminance [lx]

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Optimal lighting
• Higher illuminance means fewer work errors.
• Decreasing the illuminance increases the number
of errors
at work depending
Reduction of errors [%]
on the complexity
of the visual task.

Illuminance [lx]

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Optimal lighting
• Higher illuminance also means less fatigue.
• Less fatigue not only means more productivity but
also less injury.

reporting fatigue [%]

Percentage of employees

Illuminance [lx]

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Optimal lighting
• Lighting also affects the number of accidents at work.
• Research shows that lower workplace illuminance means
more accidents at work. As many as 2/3 of them occur at an
illuminance of less than

Number of persons injured

500 lx. Of this, 1/3 in
workplaces where the
illuminance is below
the legal minimum
of 200 lx.

Illuminance categories [lx]

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Maintenance of lighting
Good lighting needs
maintenance, as the
illuminance decreases over
time due to:
• dust on light sources,
luminaires and walls;
• aging and failure of light
sources;
• aging luminaires.

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Metal processing
• Very different workplaces and
requirements: from warehouse to
offices.
• General lighting or localized
lighting oriented to workplaces.
• Luminaires placed parallel to the
windows or according to the layout
of the machines.
• Reflector luminaires, suitable IP,
additional luminaires on machines.

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Metal processing
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Rough and averaging machining 300 22 60
Precision machining 500 19 60
Scribing, inspection 750 19 60
Tool making 750 19 60
Galvanizing 300 25 80
Precision mechanics, micro mechanics 1000 19 80

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Metal processing
Special features:
• Light sources without
stroboscopic effect.
• For lathes: additional
luminaire perpendicular to
the shaft to reduce
shadows.
• For drilling machines:
luminaire is directed from
the side-up so the markings
and the drill are clearly
visible.

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Automobile workshop
• Very different workplaces and
requirements, so the lighting must be
tailored to individual workplaces.
• Localized (area) lighting for individual
workplaces.
• Better illuminance at certain
workplaces like inspection…
• The arrangement of the luminaires
follows the arrangement of the
workplaces.
• Spotlight or luminaires with louvers.

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Automobile workshop
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Car repair 300 25 80
Body work and assembly 500 22 80
Painting, spraying chamber, polishing 750 22 80
Upholstery manufacture 1000 19 80
Final inspection 1000 19 80

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Automobile workshop
Special features:
• Luminaires for damp places
(laundries) with appropriate IP
protection.
• Additional hand luminaires for hard-
to-reach places; protection class III.
• Lateral arrangement of luminaires in
ducts.

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Electrical and electronic industry
• Very different workplaces
with small and large
appliances.
• General and localized lighting,
additional luminaires at
certain workplaces.
• When working on larger
electrical appliances vertical
illuminance is required –
wide-beam or asymmetric
luminaires.

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Electrical and electronic industry
• For the manufacturing of
electronic devices, illuminance of
500 lx or more is required.
• Spotlights or louver luminaires
with fluorescent lamps or similar
LED luminaires.
• When assembling miniature parts,
at least 1000 lx is required:
general lighting with 500 lx and
additional luminaires at
workplaces.

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Electrical and electronic industry
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Cable and wire manufacture 300 25 80
Winding: medium sized coils 500 22 80
Winding: small coils 750 19 80
Rough assembly work 300 25 80
Medium assembly work 500 22 80
Fine assembly work 750 19 80
Precision assembly work (e.g., measuring eq.) 1000 16 80
Electronic workshop, testing, adjusting 1500 16 80

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Electrical and electronic industry
Special features:
• When soldering - opal glass lamps for diffused light.
• Special luminaires for
places for the
production of
electronic
components
where adequate air
purity is required.

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Printing
• In printing workshops lighting
requirements are high as the work
requires good visual skills: colors,
images, text, fast machines…
• In printing houses and bookbinders,
a minimum illuminance of 300 lx is
required, and in the control of
multicolor printing, even 1500 lx.
• Working with visual displays
(prepress) requires very good glare
control.

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Printing
• General or workplace-
oriented lighting.
• The position of luminaires
must reduce glare to a
minimum.
• Adequate vertical
illuminance is required for
large printing machines.

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Printing
• Use of „wide angle“ luminaires
for good uniformity of
illuminance.
• Use of additional reflector or
louver luminaires where higher
illuminance is required.
• Additional luminaires with light
sources with high Ra, where
color control is performed.
Illuminance 1500 to 2000 lx.

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Printing
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Cutting, gilding, embossing, work on printing 500 19 80
machines, matrix making
Paper sorting and hand printing 500 19 80
Type setting, retouching, lithography 1000 19 80
Color inspection in multi-colored printing 1500 16 90
Steel and copper engraving 2000 16 80

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Printing
Special features:
• Working with colors (paints) requires very good color
rendering index Ra.
• Where high-gloss paper or
foil is used, indirect lighting
is recommended.

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Chemical industry
• Individual processes are so different that they usually
need customized solutions, there are practically no
general solutions.
• Good visibility of
machines, instruments…
requires adequate
vertical illuminance.
• The lighting must allow
the bottom of the
containers to be clearly
visible.

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Chemical industry
• Special versions of closed luminaires
and Ex versions for certain rooms.
• In general, localized lighting
according to workplaces can be
used.
• At certain workplaces, additional
luminaires are required to achieve
adequate illuminance.

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Chemical industry
• In laboratories, direct-indirect
lighting can be used to get enough
indirect light.
• Good Ra (>90) and very limited glare
are also needed.
• It is equally important to use
luminaires without a stroboscopic
effect.

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Chemical industry
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Remote operated processing installations 50 20
Constantly manned work places in processing 300 25 80
installation
Precision measuring rooms, laboratories 500 19 80
Pharmaceutical production 500 22 80
Colour inspection (CCT at least 6500 K) 1000 16 90

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Chemical industry
Special features:
• If very high illuminance at workplaces is needed, the general
illuminance must also be increased accordingly - adaptation.
• Where metal is soldered or
poured, the illuminance
must not exceed 300 lx.
• In some places, it is very
important that the lighting
allows for appropriate
contrasts.

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Food processing
• Cleanliness and hygiene are
very important in food
processing industry, so the
places must be bright and
friendly.
• As a result, higher illuminances
are usually planned than
necessary for the visual tasks.

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Food processing
• General lighting is usually used.
• The luminaires should be closed
with a high degree of IP
protection (humidity, steam,
heat, cold,…).
• Where food is handled, a good
Ra is very important.

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Food processing
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Sorting and washing of products, milling, mixing, 300 25 80
packing
Work places and zones in slaughter houses, butchers, 500 25 80
dairies mills…
Cutting and sorting of fruit and vegetables 300 25 80
Manufacture of delicatessen foods, kitchen 500 22 80
Inspection of glasses and bottles, product control, 500 22 80
trimming, sorting, decoration
Laboratories 500 19 80
Colour inspection (CCT at least 4000 K) 1000 16 90

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Food processing
Special features:
• To control the cleanliness
and undam agedness of the
bottles, an evenly lighting
surface with low luminance
can be used.
• The cans are inspected in a
special cabin with indirect
lighting to reduce glare as
much as possible.

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Textile industry
• In the textile industry, the
visible tasks are quite similar:
the structure of the textile
must be well visible, as well as
the colors.
• Therefore, adequate general
illuminance (at least 500 lx)
and good Ra are required.

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Textile industry
• Where higher illuminances are needed
(embroidery, sewing,…) the problem can be solved
with local workplace lighting (750 - 1000 lx).
• The color rendering index should be high enough,
the color of the light as close as possible to the
color of daylight.
• We need to avoid
„double light“.

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Textile industry
• The luminaires are usually mounted in light strips
perpendicular to the spinning and weaving machines.
• For tall machines, the
shady areas are
illuminated with local
luminaires.
• Due to the dust,
suitable Ex or D
versions of the
luminaires are
required.

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Textile industry
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Workplace and zones in baths, bale opening 200 25 60
Carding, washing, ironing, drawing, sizing… 300 22 80
Spinning, plying, reeling, winding, weaving, knitting… 500 22 80
Sewing, fine knitting, taking up stitches 750 22 90
Manual design, drawing patterns 750 22 90
Drying room 100 28 60
Automatic fabric printing 500 25 80
Colour inspection, fabric control (CCT at least 4000K) 1000 16 90
Invisible mending 1500 19 90

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Textile industry
Special features:
• Corrosion-proof luminaires should be used in paint shops.
• To control the goods,
adequate shading
needs to be achieved.
• When working with color
patterns, special booths
with daylight CCT should
be used.

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Wood working
• Visible tasks in the wood
working are very different. 300
lx is enough for sawing, 750 lx is
needed for painting and
polishing.
• The direction of the light is
important to avoid disturbing
shadows and thus danger.

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Wood working
• Line luminaires with fluorescent lamps or LEDs are
usually used.
• Additional local luminaires (on machines) are required
in certain places.
• Use of electronic
ballasts is needed to
prevent stroboscopic
effect.

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Wood working
Required values according to ISO 8995-1
Task or activity Em [lx] UGR Ra
Automatic processing e.g., drying plywood 50 28 40
manufacturing
Saw frame 300 25 60
Work at jointer bench, gluing, assembly 300 25 80
Polishing, painting, fancy joinery 750 22 80
Work on wood working machines 500 19 80
Selection of veneer woods, marquetry, inlay work 750 22 90
(CCT at least 4000K)
Quality control 1000 19 90

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Wood working
Special features:
• Ex or D versions of luminaires are
required in certain rooms.
• When controlling surfaces, we need an
almost horizontal direction of light that
produces visible shadows.

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Storage and logistics
• Storage halls are usually without
daylight and with high shelves
between which there are narrow
transport routes.
• Depending on the method of work, it
is necessary to ensure adequate
vertical illuminance on the shelves
(200 lx).

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Storage and logistics
• In warehouses, we mostly use line luminaires with
fluorescent lamps or LEDs.
• Asymmetrical reflectors
with HID lamps are also
suitable for very high
warehouses.

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Storage and logistics
Required values

Task or activity Em [lx] UGR Ra

Automatic high-bay warehouses 20 20
Warehouses for identical and large objects 50 28 20
Warehouses where goods need to be found 100 25 60
Warehouses where reading is needed 200 25 60
Loading platforms 150 25 40
Packing and dispatch places 300 25 60

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Storage and logistics
Special features:
• Adequate vertical illumination is very important.
• The luminaires must ensure adequate uniformity of
vertical illuminance
and prevent glare.

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Light sources
• Linear fluorescent and CFL lamps
• Induction lamps
• HID (MH and
sodium) lamps
• LEDs

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Luminaires
• Recessed and surface-
mounted reflector and
louver luminaires
• Line luminaires
• Reflectors

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Luminaires
• Ex and D versions of
luminaires
• Additional (reflector)
luminaires at machines
• Additional workplace
luminaires

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IP degree of protection
IP protection labeling system:

IP 45 S
IP letters, two digits and additional letters
first digit: protection against foreign bodies and contact
second digit: protection against water (moisture)
additional letters

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Fire protection labels
• Mounting on or in normally combustible materials
is not permitted.
• Permitted mounting on materials with a flash point
above 180 °C (no longer in use).
• Permitted installation on (in) furniture made of
materials with a flash point above 180 °C.
• Permitted mounting on (in) furniture made of any
material (follow instructions).
• Lamp with limited surface temperature (follow the
manufacturer's instructions during installation)
• Allowed mounting position (horizontal)
• Prohibited mounting position (horizontal)

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At the end…
When lighting industrial and trade premises, one
must not forget:
• good lighting means higher productivity as well as
greater safety;
• an investment in lighting is a profitable investment;
• the concept of lighting, light sources, luminaires…
need to be adapted to workplaces, visual tasks and
place.

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Questions?