The choice of lighting in the food industry is often complex, given the particular characteristics of these manufacturing areas. The choice of lighting depends on many factors such as the purpose of the lighting, the temperature of the working area and the layout of the installations.
In recent months, customers have been increasingly demanding Class II luminaires with LED modules and standard DALI dimming, which Airfal’s technical department advises against due to the lack of guarantees for their correct operation. To better understand why this is so, it is important to know what a Class II luminaire is.
Airfal International has recently launched a new luminaire for work areas. This light fixture, the MODULAR luminaire, combines a classic design with cutting-edge technology, achieving a high visual comfort. The Modular luminaire is ideal for offices, shopping centers and supermarkets.
Airfal International will attend the Light & Building trade show in Frankfurt, the most important lighting fair in the sector, which will be held between March 18 and 23. Airfal will take advantage of this event to launch its new catalog with a much more industrial and intuitive design, in which the ATEX range has grown significantly with six new luminaires for explosive atmospheres. Airfal will attend you on their booth located in Hall 3.1 B79. Read more
ATEX lighting is very complex and still unrecognized by many industry professionals around the world. In the previous articles, we have analyzed what ATEX lighting is and why it is necessary to distinguish it from flameproof lighting.
Airfal is the only Spanish company certified to manufacture this type of lighting and to understand why it is so complex to certify this type of product, we interviewed Carlos Jiménez, director of Airfal’s R + D + i.
Carlos explains the process that follows an ATEX luminaire from the “first draft”bto its introduction on the market.
Lighting an industrial environment can be quite difficult because of a wide variety of operations. Many aspects have to be considered as they impact on the of light reaching a surface, as well as its quality. Industrial LED Light fixtures from Airfal includes energy efficient, robust, waterproof and luminaires for hazardous locations. These light fixtures are designed to provide lighting for areas where water, vibration, maintenance or temperature negatively affects conventional illumination.
Replacing obsolete lighting by LED lighting in an industrial environment can provide savings in consumption of up to 70%. Productivity and safety of workers largely depend on the quality of lighting. Industrial light fixtures should also resist extreme temperatures and harsh conditions such as vibrations. Airfal has been able to produce industrial lighting fixtures that maximize efficiency and light output while providing adequate level of safety.
Areas of application of industrial led lighting
Industrial Led lighting is now commonly used in industrial environments, bringing efficient illumination for a safer workplace and a pleasant atmosphere for industrial workers. Our LED lighting fixtures have been designed specifically to replace conventional lighting in a wide variety of industrial applications, both indoor and outdoor.
Industrial lighting from Airfal is used in warehouses, factories, industrial locations, food industry, hazardous areas, logistic and distribution centers, cold storage… Furthermore, Airfal light fixtures are dust proof and waterproof, and some of them are also resistant to extreme temperatures.
Airfal LED luminaires are designed to meet the most demanding environments while offering maximum energy savings.
Industrial lighting upgrade
An industrial lighting upgrade can reduce energy costs and improve workforce performance in a significant way. On many occasions, however, industrial lighting projects result are missing opportunities. The focus is solely on energy efficiency, or on industrial light fixture cost, but other factors such as maintenance costs should also be taken into account. You should not focusing solely on energy savings, but also take into account maintenance costs, as well as the quality of the light and its potential impact on safety or productivity of workers. Industrial lighting accounts for a substantial portion of the energy used in industrial facilities and a careful analysis should be previously undertaken.
Airfal International is expanding its range of luminaires with high technical specifications and launches Frozen, a luminaire suitable for extreme temperatures. This model is specially designed for freezing and deep-freezing areas, with IK07 and IP68-2 protection. Read more
Good lighting combines three aspects: high luminous efficiency, long life and good color rendering.
The lighting of industrial premises should:
- Facilitate the Execution of a Task: the Visual Performance Concept.
Normal vision can only be exercised with minimum light. A good level of lighting allows for a good productivity, which means fewer errors or accidents, and reduced eyestrain.
- Ensure Well-Being: the Fundamental Concept of Visual Comfort.
In addition to the required level of illumination, it is also essential to ensure the following:
- A good quality of the light emitted by the sources
- The uniformity of the illumination
- The adequate balance of illumination to avoid glare in particular.
Illuminating the industry work areas
The illumination level has to be adapted to the nature and the precision of the work that needs to be performed. To illuminate the work area, it is reccommended to use local lighting, adapted to complement the general lighting of the premises.
- For inland circulation: 40 Lux Minimum Illumination
- For changing rooms and bathrooms: 120 Lux Minimum Illumination
- For blind premises assigned to permanent work: 200 Lux Minimum Illumination
Lighting for Outdoor Spaces:
- For taxiways: 10 Lux Minimum Illumination
- For outdoor areas assigned to permanent work: 40 Lux Minimum Illumination
Lighting for Specific Work Areas:
- For average mechanics and office-based typing work: 200 Lux Minimum Illumination
- For machine processing and office-based drawing work: 300 Lux Minimum Illumination
- For fine mechanics, engraving, drawing and color comparison: 400 Lux Minimum Illumination
- For precision engineering, fine electronics and various controls: 600 Lux Minimum Illumination
The level of illumination required in the industry depends on:
- The size of the details that need to be observed
- The contrast between the object / form and the bottom (the greater the contrast, the higher illuminance is required).
The Following Aspects Must Also Be Considered :
The speed of the work execution
- The movement of the monitored objects (the faster the movement, the higher illumination is required)
- The age of the operators
In industries which require fine and precised mechanical tasks, as well as the electronics industry, specific lighting reinforcements on the workstations must be installed. Some industrial sectors, the chemical sector in particular, require the use of protected luminaires.
Industries in which color rendering is extremely important, such as the printing industry, require the use of appropriate lighting lamps. In other industries such as paint manufactoring, plastics or resins, the industrial process requires the use of special UV types or IR light emissions.
A high risk or hazardous area is where a mixture of air and potentially explosive substances such as gases, vapours, mists or dusts, could spread. Typical examples of hazardous environments are refineries, drilling platforms, chemical and power-generation facilities, mines… In these locations, it is required to ensure safety against occurrence of arcs, sparks and excessive temperature. Currently, lighting for shale gas drilling platforms that are expanding in many countries, requires compliance with a gas facility classified as Zone 1 (ATEX hazardous area) and Zone 2 (standards Class I Div 1 and Class I Div 2 in the USA).
Industrial lighting must often provide illumination in areas where usual lighting is inadequate. Some factors related to the very nature of the activities carried out have to be taken into account, due mainly to the materials handled and the by-products produced. Whether the manufacturing process deals with the processing of hazardous petrochemicals or relatively benign food products such as food grain, there is always the underlying risk of accidental ignitions of flammable or explosive of materials. An atmosphere saturated with gasoline or solvent vapours can literally turn an enclosed area into a potential bomb capable of releasing enough force to destroy the entire building.
The main way to prevent explosions in such industrial areas is to remove potential ignition sources. Potential ignition sources is anything which has the ability to produce sparks, flame, or otherwise is capable of producing enough heat to ignite any flammable materials which may be present. In industries and facilities, the primary sources of potential ignition are usually electrical, they are numerous, and it is usually impossible to remove from the industrial process. They can be machinery, equipment, electrical switches and controls, or lighting, and they are all necessary for the manufacturing process. They represent potential sources of ignition due to their potential for creating heat, sparks, and even open flame.
Of all the potential sources of electrically caused ignitions, lighting is perhaps the most commonly encountered. No matter the facility, lighting will play an important role in hazardous areas. In order to protect against this potential for ignition, lighting used in hazardous locations must be specially designed and certified by regulators for use in these areas. This type of light fixtures falls into the categories of “Explosion Proof” and plays a critical role in protecting the industrial facilities against catastrophic accidents. Airfal is a manufacturer of safe explosion protection lighting for use in hazardous areas and harsh environments, which are fully certified.
Explosion proof fixtures provide protection by preventing any ignitions within the fixture from igniting the atmosphere outside of the fixture. Explosion proof fixtures are not fully sealed, but they have the ability to prevent the ignition of the atmosphere outside the light fixture should it contain flammable vapors, gases, or combustible dusts, whereas in a standard light fixture, the bulb, contacts, wiring, and any switches are all directly exposed to the local atmosphere. The spark from a loose contact or the movement of the switch and even the heat of the bulb can be a danger.
Airfal features several light fixtures for hazardous areas in its range of products, including LED light fixtures which are environmentally friendly and offer energy efficiency and light control for difficult and harsh locations:
PYROS is an explosion proof light fixture made of polycarbonate cover and aluminium ends with great mechanic strength. Lamp holders mounted over removable reflector make maintenance work easier.
SECURE is an ATEX tubular light fitting which is IP68 protected. This allows a total protection against dust and against water penetration during a long time. Impact protection is IK10, the best protection degree available for a luminaire. SECURE is specifically designed for ATEX 2 and 22 zones, and is adequate for places where occasionally may appear dust or atmosphere potentially explosive, but never as usual condition.
MINEX is designed for lighting in mining applications and underground spaces susceptible to firedamp. It can also be used in other industrial places, indoor, outdoor or under shelter.
LUMEX: Light fitting designed for industrial space lighting that are NOT mines, especially places with very high ceilings.
VITRA: explosion proof light fixture made of borosilicate tempered glass cover and aluminium ends. This light fitting is designed in order to obtain resistance against chemical products such as hydrocarbons or other chemical products that are aggressive against polycarbonate. This is achieved by using a tempered borosilicate glass tube.
FLAME has been designed to operate in environments in which an explosive atmosphere can be formed or can be present according to ATEX 94/9/CE directive, through the combination of Improve Security Protection “e” for gases and “tb” body protection for dust. Furthermore, the combination of M1 non flame propagator polycarbonate, as well as antistatic additives in the cap plastic makes it perfect for areas with explosion or fire risks.
Contact us today, and we will be more than happy to help you finding out the right explosion proof light fitting.
A high quality industrial led lighting system will significantly improve operating costs of your company, as well as working conditions, and provide added safety. We highlight in this article some of the reasons why you should consider upgrading your industrial lighting system to LED, if you haven’t already.
Industrial LED Lights are longer lasting
LED light bulbs tend to last up to 25 times longer than traditional industrial light bulbs. . One of the amazing advantages of installing LEDs is their long operating life. . Unlike other industrial lighting technologies, LEDs don’t burn-out, but they gradually fade over time. Some industrial LED light fixtures have very long operating life, with a lifespan of more than 80,000 hours.
Improved energy efficiency with industrial LED Light fixtures
LED lights usually cost more to install initially. However, those costs can be reduced due to their longer lifespan, and overall electricity usage. It is generally agreed that LED bulbs tend to use around 75 percent less energy than other types of bulbs.
Higher light quality thanks to led light fixtures
Improvements in lighting technology for led bulbs have increased lighting efficiency, as well as color quality. Improved lighting quality can affect worker performance and accuracy in a variety of activities. A new lighting installation can have a marked improvement on employee output in industrial installations.
LED lights produce less heat
Halogen and incandescent bulbs produce a lot of heat. If there are combustible materials near the industrial light fixtures, then this added heat can be dangerous and increase the fire risk in your industrial facility. This also results higher energy spending since more air conditioned is needed.
By installing led light fixtures in industrial environments, we can improve safety in industrial areas, such as warehouses and manufacturing facilities. A new LED installation also offer higher brightness that reduce the number of LEDs required for a fixture while improving worker safety. Brighter lighting on the shop floor can lead to fewer safety problems, while improving worker output.
Maintenance of the industrial lighting installation
Regular maintenance used to be vital to ensure that industrial facilities received the desired quantity and quality of light, with traditional lighting systems. Periodic maintenance used to produce a range of benefits, including a brighter workplace, a higher level of security in the industrial facility, and enhanced productivity. Airfal industrial LED fixtures are nearly maintenance-free, which results in less time and less expenses spent in replacing light bulbs. Operational downtime is also avoided, since LED bulbs have a longer time span .
LED lights for industrial facilities are more sustainable
Green lighting is a key trend, also in lighting environments. If your company is looking to “go green”, then installing LED light fixtures into your factory on warehouse can be very effective. Becoming more sustainable can help to improve your company image, as well as reduce operating costs. LED light fixtures are more sustainable as they use less energy, and they require less overall maintenance.
The lighting manufacturing company from Aragon in Spain has made some improvements to its TR2 waterproof model, in terms of both increasing its power as well as being able to withstand temperatures of up to 80 °C. Customer demand for the product, as well as Airfal’s ability to create and customise its lighting, have made the new version of the TR2 a possibility, and it is perfect for industrial extractor hoods.
This infographic sheds light on industrial lighting trends and what has driven innovation in the field. Lighting an industrial warehouse can raise many issues. Because of a wide range of operations, it is vital to take into account many aspects that can impact the level of light reaching a surface, as well as its quality.
The infographics also features some basic concepts related to the world of industrial lighting.
– Lumens: a measure of the total amount of visible light emitted by a lamp
– Lamp life: it is the “life expectancy” of a lamp.
– The color rendering index, a measure of the light source that reveals the true color of objects in a room
The infographic also presents several types of light bulbs, such as incandescent bulbs, HID lamps (high intensity discharge lamps), fluorescent lamps, and LEDs.
According to the infographic there are several drivers of innovation in industrial lighting:
The original infographic can be found on this page:
Some simple steps will make the lighting of a factory or warehouse energy efficient, which can lead to greater profits
Most often inefficient use of lighting in factories and warehouses causes wastage and losses. This wastage can be measured and reduced by taking adequate steps, starting with the audit of the electrical installation. With an energy audit, we can identify the possible areas of wastage like inefficient and excess use of lights. By taking appropriate measures, energy can be used more efficiently to light up a factory or a warehouse.
Every factoryor warehouse has savings to uncover that can be as simple as changing a light fixture, or using Led light bulbs. The return of investment of LED lighting can be easily calculated, and the payback is usually significant. The counter argument has always been that it is a big expense to install LED lighting, but if you are replacing a traditional light fixture with a LED version, the numbers speak by themselves.
It is worth committing to an energy efficiency change in a factory or warehouse. Changing to new light fixtures will have the following positive impacts:
– Upgrading lighting is one of the easiest way to lower energy costs. When replacing a light bulb, burning fewer watts per unit of light generated, and producing less heat in hotter months of the year, can result in savings of up to 75-80%.
– The challenge can be the upfront investment, but the average LED bulb will last 10 to 25 times longer than a traditional light. With up to 80000 hour lifespan, there is no need to hire expensive access equipment to change lamps and bulbs located in áreas that are of difficult Access in the Factory or in the warehouse.
– New light fixtures provide more powerful ways to control your light spending. Wireless technology has made the ability to control lighting easier than ever. LED light fixtures can be connected to a network that controls the lighting in your plant or warehouse via a software, from a computer, a smartphone or a controller itself. Wireless technology helps to control every aspect of lighting in the plant or warehouse, from hue to intensity, resulting in a more productive work environment.
– With 100% instant light, you can eliminate the “start up” or “cool down” times of old factory lights
– Electronic ballasts are useful too. Electronic ballasts are twice as expensive as conventional magnetic ballast but the energy consumption is about 25%. Conventional magnetic ballast takes about 8 to 10 watts whereas electronic ballast takes about 2 watt per 40 W tube. The payback period of an electronic ballast is about 2 years. Although the initial cost is higher, the lifetime savings are significant.
– Industries where lumen requirement is very high should use Energy Efficient Lights fixtures. By improving light quality in your factory warehouse, you can make it much easier to carry out tasks, which affect positively your financial results.
Energy saving lighting for manufacturing or assembly plants, and warehouses will definitely give you a competitive edge.
Manufacturing facilities will differ in their lighting requirements. The recommended light levels vary significantly depending on the activity. Other factors, such as energy effciency, or cost of maintenance have also to be taken into account.
The ambient temperature does have significant impact on the choice of the light fixture. In many industries, heat is a challenge as it can affect the quality of light, but also damages the electronic components of the light fittings.
This infographic explains why high temperature areas need specific light fixtures, and aims to guide you in the choice of high temperature light fixtures.
Industrial lighting must sometimes provide illumination in areas where usual lighting is inadequate due to the risk of accidental ignitions of flammable or explosive of materials. Airfal range of products include fluorescent light fixtures, that are suitable for Zone 1 and Zone 2 lighting installations with ATEX certification.
A high risk or hazardous area is where a mixture of air and potentially explosive substances such as gases, vapours, mists or dusts, could spread. Typical examples of hazardous environments are refineries, drilling platforms, chemical and power-generation facilities, mines… In these locations, it is required to ensure safety against occurrence of sparks and excessive temperature or arcs with adequate light fixtures. Currently, lighting for such areas requires complying with standards classified as Zone 1 and Zone 2.
Zone-1 contains a hazardous gas/air mixture under normal operating conditions. Zone-2 is hazardous only in abnormal operating conditions, and if so, it will only exist for a short time.
Our Explosion Protected Lighting For Hazardous Locations include fluorescent light fixtures that have been developed for use in hazardous areas and harsh environments and are certified. These fluorescent light fittings are manufactured with the highest quality materials and finishes.
Well balanced levels of illumination are essential in establishing safe and productive working conditions. Companies should take into account lighting in the industrial work place very seriously. Optimizing industrial lighting requires consideration of work tasks, environmental conditions and economic considerations. The benefits of adequate lighting include greater productivity and accuracy, improved safety and security, and improved moral for workers.
Several factors will have to be carefully analyzed such as the task, the working environment, the quantity and the quality of lighting. Well balanced illumination is essential for the establishment of a safe and productive work environment; optimizing illumination in the industrial workplace requires a number of considerations including level of lighting, type of equipment, environmental aspects, financial requirements, optic, lamp, temperature, goals, or type of work….
Lighting in the Industrial sector can be quite complexe. Due to a wide range of operations and tasks, many aspects have to take into consideration as they will impact the amount of light reaching a work surface as well as its quality.
Required level of lighting in the industry
The required quantity of light (illuminance) depends mostly on the visible task the worker, or the type of the industrial task performed.
Here are some examples of industrial recommended lighting levels:
|General Engineering||Rough work||
|General Engineering||Medium work||
|General Engineering||Fine work||
|General Engineering||Very fine work||
|Outdoor Areas||Mechanical loading||
|Outdoor Areas||Manual loading||
|Warehousing||Small storage, packing||
Quality of lighting in the industrial sector
Factors influencing the quality of industrial lighting have a significant impact. These factors include flicker and glare, degree of contrast or shadows. There should be good contrast between objects of interest and background. Greater lighting in areas next to but outside the immediate work environment can make visibility difficult.
Industrial lighting requirements
Industrial Lighting Standards address the importance of evaluation of energy consumption, and other key features aimed at improving overall performance in the workplace.
Until recently, a manufacturer of electrical products for hazardous locations would have to design equipment to meet the national standards of each country in which he wanted to sell its products. Today, a manufacturer can go to almost any Certification Agency and receive a Certification Mark which will be accepted in almost any country in the world. However there are still differences between certifications. For instance, ATEX is a regional scheme in the European Union, and is mandatory. IECEx is a global certification, is voluntary and is open to all countries.
Equipment for use in hazardous locations must be certified to an appropriate national standard and marked as such by an accredited third party testing organization. There are currently 3 different certifications of products used in hazardous locations
North American Certification
The equivalent of the ATEX directive in the US is the HAZLOC standard. This standard given by the Occupational Safety and Health Administration defines and classifies hazardous locations such as explosive atmospheres. It aims to control the risks related to explosion in certain environments.
It comprises two elements:
– testing and evaluation of products being used
– inspection of the factory
In North America, all electrical equipment must be approved/certified as follows:
• In the USA, by a Nationally Recognized Testing Laboratory (NRTL) accredited by OSHA.
• In Canada, by a Certification Body accredited by the Standards Council of Canada (SCC).
• The proof of certification must be displayed on the equipment in the form of the mark or label of the certification body.A certificate/declaration of compliance is not sufficient.
The Certification Body that granted the certification must inspect each factory (defined as the location where the product is manufactured and labelled) four times per year. This is the same for every Certification Body, and each must perform their own inspections. This is significantly different from ATEX and IECEx, certifications where a manufacturer may have Certificates issued by a number of different Notified Bodies, but the audit is only performed by one.
In North America, hazardous locations have traditionally been defined by a combination of classes and divisions .
In the U.S. and Canada, the certification of hazardous locations electrical equipment is cnow hanging and is evolving to the zone system. There is now an international 3-Zone area classification system for equipment used in hazardous locations.
• Zone 0 – An place in which an explosive gas atmosphere is continuously present
• Zone 1 – A place in which an explosive atmosphere is likely to occur in normal operation
• Zone 2 – A place which an explosive gas atmosphere does not normally exist.
In Canada, all new installations must use the 3-Zone system. Existing installations may continue to use the 2-Division system or opt to re-classify using the 3-Zone system.
In the U.S., all installations (both new and existing) can either continue using the 2-Division system or re-classify their product using the 3-Zone system. Read more
A new waterproof light fixture has now been added to the Airfal range of luminaires: the RINOX model; This light fixture is impact protected to IK10 protection index, thanks to its tubular body, made of 3.5mm thick UV protective polycarbonate.
High ceilings can be a challenge when incorporating lighting applications. When dealing with high bay lighting, we will have to face many challenges, such as minimizing contrast, reducing glare, or meeting strict safety and hazardous environment requirements. Low maintenance, energy saving light fixtures, designed to drive down costs are also needed. High bay lighting generally applies to libraries, atriums, gymnasiums, cafeterias, but also warehouse spaces, and high bay workshops.
T-5 fluorescent lighting is often used for lighting in high ceiling areas, meeting the recommended light levels and increasing the quality of light. Until very recently, LED technology was not an option due to high prices. However, high-bay LED fixings are now available, providing good quality of light at reasonable price, with paybacks from energy savings. Employees and customers now feel better in their working environment, meeting safety standards at a competitive cost.
Airfal decided once again to be part of an important lighting show, Light & Building 2014, which took place last March in Frankfurt . The Spanish company has been exhibiting since the first edition of Light & Building 2014. Read more
Following our previous post, we enclose a guide to the recommended light level for different industrial and commercial activites:
Chemical activities; Transport industries such as train stations, gas stations, car garages, naval docks; Offices and administrations, Shops, merchandise shelves, small shops….
This guide gives the recommended minimum lighting levels for different types of work activities
Lighting should be sufficient to enable people to work, use facilities and move from place to place safely and without experiencing eye-strain.
If people have difficulty doing their job because lighting is too low then setps should be taken to improve it. However, if an area measured falls outside these levels, it does not necessarily mean that the whole lighting system needs to be modified. Other measures such as task-specific lighting might be more appropriate. Generally speaking, the finer the detail, the higher the light level required.
Outdoor light level is approximated at 10,000 lux on a clear day. In enclosed areas like commercial buildings, the light level may be as low as 25 – 50 lux. Additional lighting equipment is often necessary to compensate these low levels of lighting.
A minimum level of illumination is required to read correctly and without fatigue objects and thus perform correctly (and sometimes safely) the intended task .
The level of illumination required depends on the activity to perform
Light Level or Illuminance, is the total luminous flux incident on a surface, per unit area. Usually, standards and norms define the light levels by task. The difficulty is to define the space in which the task is to be performed. The amount of light being given off by a particular source, in all directions, is called luminous flux (or “luminous power” or “lux”) and is a measure of the total perceived power of light. It is measured in lumens.
Measuring Units Light Level – illuminance
Illuminance is measured in foot candles (ftcd, fc, fcd) (or lux in the metric SI system). A foot candle is actually one lumen of light density per square foot,one lux is one lumen per square meter.
• 1 lux = 1 lumen / sq meter = 0.0001 phot = 0.0929 foot candle (ftcd, fcd)
• 1 phot = 1 lumen / sq centimeter = 10000 lumens / sq meter = 10000 lux
• 1 foot candle (ftcd, fcd) = 1 lumen / sq ft = 10.752 lux
How to measure ?
A light meter (also called lux meter) is very useful. A light meter measures the amount of visible light illumination in a given area tested. Illumination is expressed in units of LUX (metric) orFoot candles (English).
Lighting in food processing facilities has its own specific lighting constraints. Some areas of critical production require specifically designed lighting solutions and light fixtures. Food processing and preparation areas are extremely critical environments. High visibility, and also well-distributed lighting is required in all food processing industries
Industry standards and regulations have very stringent requirements, which mean lighting for the food processing industry must meet particularly demanding criteria. The lighting fixtures must withstand rigorous cleaning protocols and also support extreme high and low temperatures. Read more