Lighting

Industrial lighting
Application guide for general lighting.

Point and line sources, fluorescent and HID solutions.
Application guide Industrial lighting
Contents
General information
04
2
2.1
2.2
2.3
2.4
Lighting design decisions

Comparison: lighting
Comparison: installation
Comparison: maintenance
Decision scheme
05
06
07
08
09
3
3.1
3.1.1
3.1.2
3.1.3
Lighting design examples

Industrial hall, height 18 m
HID point sources
Fluorescent line sources
Fluorescent point sources
10
11
12
13
14
3.2
3.2.1
3.2.2
3.2.3
Industrial hall, height 12 m

HID point sources
15
16
17
18
3.3
3.3.1
3.3.2
3.3.3
Industrial hall, height 7.5 m

19
HID point sources 20
Fluorescent line sources 21
Fluorescent point sources 22
1 General information
Point or line sources, fluorescent or HID?
High-intensity discharge lamps are used in narrow-
For general lighting in industry, two basic types of lighting

solutions are available:
1. Lighting solutions based on linear light sources. Linear
solutions typically include fluorescent lamps. These
lamps may be used in single-, twin- or triple-lamp
luminaires, mounted either individually or in continuous
lines. For reasons of economy, the most widely used
lamp types are TL-D 58 W, TL-D 36 W and TL5 49 W,
which combine energy efficiency with a length that is
easy to handle.
or wide-beam rotationally symmetrical luminaires,

in floodlights, or in low-bay luminaires with specular
reflectors. For reasons of economy, the most widely
used lamps are high-pressure sodium, e.g. SON
Comfort, and metal halide, e.g. HPI Plus. There is a new
lamp, the CDM-T 250 W, which combines outstanding
colour rendering with efficient light. Fluorescent
high bay point light solutions typically include 3
or 4 TL5 High Output or Very High Output lamps
(54/80/95/120 W), which combine the typical qualities
of fluorescent lamps, such as instant start and good
colour rendering. There is a limited range of compact
fluorescent lamps (typically 60/85/120 W) which offer
similar qualities.
2. Lighting solutions based on point light sources.

Point solutions are solutions with high-intensity
discharge lamps and with (compact) fluorescent lamps.
2 Lighting design decisions
General design considerations

For buildings with a free height of up to 6 metres,
fluorescent lamps are the most widely used lamps in
continental Europe. In the USA and the UK, the use of
HID lamps in low-bay reflector luminaires starts at a
height of 4 m. However, the glare requirements in these
countries are less severe than in continental Europe.
Fluorescent lamp luminaires can be mounted on the
ceiling or on a power distribution system (trunking
system). In general, continuous or semi-continuous light
lines are installed. Installers try to reduce the installation
costs by installing the lowest possible number of light lines.
Both linear and point light sources can be used
successfully for buildings with a free height of between 6
and 12 metres. The choice depends on local custom, the
type of industry and the required lamp characteristics.
Both lighting systems have their specific features and
benefits. The lighting designer should consider the
advantages and disadvantages of both systems and then
make a decision on the basis of this. Paragraphs 2.1 to 2.3
of this document give design decision support.
High-intensity point light sources are generally used for
buildings with a free height of 12 m or more. Compared
with fluorescent linear luminaires, the number of light
points can be significantly reduced (by up to a factor of
3), making maintenance and installation more economical.
In cases where the typical characteristics of fluorescent
lamps are required, fluorescent lamps can be used in
luminaires with narrow-beam reflectors or in high-bay
solutions (3 to 4 lamps in a luminaire). Especially when
TL-5 High Output lamps (e.g. 54 W or 80 W) or TL-5
Very High Output lamps (95 W or 120 W) are used,
installations can be realised in a very economical way.
consideration as well. All systems have typical features

and benefits and in the end these determine the choice of
system. A comparison of line light and point light systems,
fluorescent solutions and HID solutions (typically SON
Comfort, HPI or CDM-T) is given on the following pages.
This comparison is based on three characteristics: lighting,
installation and maintenance.
1. L ighting aspects influence the number of luminaires
required, the uniformities that can be achieved
by standard solutions, the modelling (shadow)
characteristics as well as the lamp characteristics, e.g.
colour appearance and colour rendering.
2. Installation aspects help determine the number of
luminaires required, whether or not a trunking system
is available, how emergency lighting can be provided by
the same system, the available lamp choice, the ambient
temperature in which the system operates effectively,
and the influence of the ambient temperature on the
lamp flux.
3. M
aintenance aspects help determine the failure rate at
an early stage in the lamp lifetime and during lifetime,
the number of luminaires to be maintained and the
lumen output depreciation.
Influence of local aspects in final choice
The final choice is heavily influenced by local and regional
aspects. Identical situations will not necessarily be dealt
with in the same way because cultural differences and
conventions quite often play a part in determining the final
choice.
System comparison
Although the height of the space might play an important
role in the decision-making process, there are a large
number of other aspects that need to be taken into
2.1 Comparison: lighting

Number of luminaires
CDM point sources
HID point sources
Many
Many moderate design
Moderate
Moderate few
dependent
design dependent
Lamp wattage range
Typically 35 80 W
Typically 54 120 W
250 W
Typically 250-400 W
Uniformity horizontal illuminance
Good
Design dependent
Design dependent
Design dependent
Shadow pattern
Soft
Stronger than with line sources
Harsh/lifely
Harsh/lifely
Colour temperature Tc
3000 6500 K
3000 6500 K
3000, 3200, 4200 K
2150-6700 K
8000 K, 17 000 K
8000 K, 17 000 K
Colour rendering Ra
Typically >80
Typically >80
>80
50-70
Dimming possible
Yes
Yes
No
Restricted
Instant on
Yes
Yes
No
No
Tc dependent
The number of luminaires for a point source installation
can be significantly lower than if linear light sources are
used. In a TL-D luminaire, two 58 W lamps are used on
electronic gear, providing 10400 lumen, while one SON
Comfort or HPI Plus 400 W BU lamp provides a luminous
flux of 37000 or 32000 / 42500 lumen. However, HID
lamps with a lower lamp flux are also available (CDM-T
250 W: 23000 lumen, HPI Plus 250 W: 18000 lumen; SON
Comfort 250 W: 22000 lumen), resulting in approximately
half the number of luminaires that would be required for a
fluorescent lighting installation.
are preferred for point light sources in order to ensure

uniform illumination, with overlapping beams from the
individual luminaires.
Uniformity
Fluorescent lamp luminaires will always provide good
illuminance uniformities unless unsuitable mirror optics
have been used or the luminaires are spaced too widely
apart. The uniformity will also only be influenced to a
limited extent at higher levels or where obstructions are
present. The use of point light sources requires a proper
lighting design because although the uniformity at floor
level may be correct, the uniformities at higher levels and
in the vertical plane may be poor when very efficient
narrow-beam luminaires are used. Due to the limited
number of luminaires used, the screening of even one
luminaire by an obstruction can influence the illuminance
dramatically. Special attention should be given to careful
lighting design, using narrow-beam luminaires where
absolutely necessary. In general, wide-beam luminaires
should be used, ensuring good uniformity under practical
industrial conditions. On the whole, greater heights
Colour temperature and colour rendering

A wide range of fluorescent lamps is available. For each
colour temperature, a choice can be made from 2 or
more colour rendering values within the available range of
lamp types. Compact fluorescent lamps are available in a
limited range of colours (2700 K - 5000 K) but with good
colour rendering characteristics (Ra > 80).
Shadow pattern
Linear lamps only create soft shadows. This characteristic
is influenced by the large number of luminaires needed to
achieve the required illuminance. Point light sources cause
harsher shadow patterns. In practice, the shadow pattern
of a small object will resemble windmill blades, as a
result of the shadows produced by four or more separate
luminaires.
The range of HID lamps is more limited. In addition, the

colour appearance of these lamps is often linked to the
colour rendering characteristics. New developments are
taking place, aimed at making available HID lamps with
good colour rendering characteristics (Ra > 80) and a
warm or neutral white colour appearance. Despite the
limited lifetime, these CDM-T lamps are used in industrial
applications because of their pleasant light.
2.2 Comparison: installation

CDM point sources
HID point sources
Initial costs
Moderate
Moderate
High
Lowest
Total cost of ownership
Low
Lowest
High
Moderate
Many
Many - moderate
Moderate
Moderate - few
Trunking system
Optional
Unusual,
Unusual,
Unusual,
individually mounted
Emergency Lighting
Integrated
Integrated
2nd system
2nd system
(option)
(option)
required
required
Lamp choice
Large
Large
Limited
Limited
Ambient temperature
-10C< Tamb < 40C
-10C< Tamb < 40C
-20C< Tamb < 40C
-20C< Tamb < 40C
Temperature dependence of
Critical
Critical
Independent
Independent
lamp flux
except TL5 TOP
except TL5 TOP
(installation)
Number of luminaires / trunking system

The number of luminaires to be installed is closely related
to the lamp flux of the available lamps. More luminaires
installed on an individual basis can increase the installation
costs significantly. For this reason, trunking systems
are available to transport the electric power and to
suspend/ mount the luminaires in industrial fluorescent
lamp systems (with their limited lamp flux). Fluorescent
luminaires can either be mounted in light line systems
(e.g. TTX400 or Maxos) or individually. Fluorescent
high-bay solutions have recently become available. In
general, point light sources are mounted and cabled
individually.
Lamp choice
The fluorescent lamp range offers a tremendous choice
of lamps. The length ranges from 0.60 m (2 feet) to 1.5
m (5 feet) (or even 6 or 8 feet in the UK and the USA),
corresponding to 18 W and 58 W (or 70 W and 100 W)
for TL-D, and 14 W - 120 W for TL5. The range of HID
lamps is limited. For industrial applications, the most widely
used lamps are 250 and 400 W, mainly SONComfort, HPI
and CDM-T, each of which has its own characteristics.
All lamp types are housed in the same type of luminaire,
although the gear must be matched to the lamp type.
dramatically reduced at above 50C . These lamps operate

most efficiently at an ambient temperature of 25 - 35C,
with the exception of the Polar range, which operates at
lower temperatures. Temperatures in industry can vary
from deep-freeze levels at -30C to 60C or even higher
in high halls with heat-generating processes. This means
that fluorescent lamps used in industry do not always
operate in their optimum temperature range, resulting
in the installation being significantly less efficient than
expected.
The lamp flux of HID lamps is almost independent of the
ambient temperature. The main limitations to the use of
HID lamp systems are the igniter (good ignition down to
-20C) and the ballast in the housing (specified lifetime up
to 35, 40 or 45C, depending on type). Simple measures
can be taken to ensure proper operation of HID lamps
below and above these limits: the ballast and igniter can
be located in a temperature-controlled cabinet instead of
being integrated into the luminaire housing.
Ambient temperature /
temperature-dependent lamp flux
Linear fluorescent lamps do not ignite at temperatures of
below -5C (high frequency: -10C ), and the lamp flux is
2.3 Comparison: maintenance

Fluorescent point sources CDM point sources
HID point sources
Early drop-outs
Hardly any
Hardly any
Few
Few
Spot replacements
Not necessary
Not necessary
Necessary
Necessary
# of luminaires to maintain
Many
Few
Few
Few
Lumen output depreciation
Very slow
Very slow
Moderate/fast
Moderate/fast
Service lifetime (hours)
Super 80 10000 h
Super 80 10000 h
CDM-T /942 10000 h
(based on cycle of 12 hours,
Super 80 (HF) 17000 h
Super 80 (HF) 17000 h
HPL-N 6000 h
MFreplacement=70%)
Xtra 35000 h
Xtra 35000 h
SON Comfort 13000 h
Xtreme 50000 h
Xtreme 50000 h
(large # of lamps)
Early failures and spot replacement

The quality of fluorescent lamps is very consistent: early
failures are not likely. Due to the complex chemical
system and mechanical manufacturing process used for
HID lamps, early failures of some lamps may unfortunately
occur long before the specified lifetime has expired.
Luminaires to maintain
During installation, the installer generally works in a hall
which is still empty. This allows the installer to work in
a very efficient way. However, by the time maintenance
becomes necessary, industrial halls will have been
equipped with all kinds of floor-standing and ceilingmounted equipment. Luminaires can then no longer
be reached easily, and certainly not very efficiently. As
line light installations require more luminaires than
those using point sources, more time will be needed for
maintenance, which translates into higher costs. The time
for maintenance in industry should not be underestimated:
30 minutes for each luminaire is a reasonable figure.
HPI Plus BU 10000 h
Service lifetime
The lifetime of lamps can be defined in many ways. For
industrial applications, the illuminance should not fall
by too much. For this reason, the service lifetime is
defined as the time at which the combination of failure
rate and lumen depreciation has reached a level of 70%.
The service lifetime which is defined in this way differs
significantly for the different types of lamps. Differences
in lifetime of a factor 3 within the fluorescent or HID
lamp families are realistic. Depending on the actual
operating hours in the specific industrial application,
the service lifetime should actively be taken into
consideration when deciding which lighting system to
use and how much maintenance will be required.
2.4 Decision scheme

Typical characteristics:
The application characteristics mentioned below can be
decisive in the choice of lighting installation, irrespective of
the initial costs or the total cost of ownership.
fluo line
fluo point
CDM point
HID point
information
Room and environmental characteristics

Low mounting height (< 6 m)
Very high mounting height (> 18 m)
o*
o*
Space is not climate controlled (e.g. outdoor)
Extreme ambient temperatures (e.g. cold stores, heat-generating industry)
-*
-*
* Polar version
o*
* SON only
Vertical illuminance is needed
Large obstructions within the space (uniformity)
Instant restrike is required
Colour stability is critical
Colour rendering > 80 is required
Improved colour rendering (e.g. print industry)
o*
o*
o*
* 80/95/120 W
Lighting characteristics / lighting quality

Dimmable installation is needed (e.g. daylight linking, different lighting levels
at different times of the day)
* De Luxe Pro,
Graphica Pro,
CDM-T 942
Maintenance
Difficult maintenance (e.g. 24/7 operation, process industry)
o*
+*
Extra safety required (e.g. food and pharmaceutical industry)
+*
+*
Fixtures are likely to get bumped
* Xtra, Xtreme
* Secura
+ applicable solution, preferred

o applicable solution
- not applicable
3 Lighting design examples

This chapter includes some calculation
examples to compare high-bay (HID or
fluorescent) or line lighting solutions for
industrial buildings.
The ground plan of the industrial building is
56 m in length and 32 m in width. The position
and size of the task area and the surrounding
area within this floor plan, as used in the
calculations are shown in the figure below.
Three different heights have been chosen
for the calculations, 18, 12 and 7.5 metres.
According to the height, different required
lighting levels have been chosen.
The following are shown for each situation:
the lighting solution,
the lighting results (3D, isolines and facts)
the LENI (numeric indicator of energy
performance)
10
32.0 m
30.0 m
26.0 m
6.0 m
2.0 m
0.0 m
0.0 2.0
4.0
Task area
Surrounding area
50.0 54.0 56.0 m
3.1 Industrial hall, height 18 m

Calculation conditions
Room height: 18 m + 4 m roof
Room dimensions: 56 m x 32 m
Required lighting level: 300 lux
Reflection factors: 30%, 30%, 10%
18 m height
Overview
No lighting controls
Constant illuminance and daylight linking controls
Light levels
HPK380 1x 400 W P-MB

Eav = 316 lux
Load = 7.56 W/m2
LENI = 30.24 KWh/m2/y
TPS350 4x 80 W NB
Eav = 311 lux
Load = 8.2 W/m2
TMX400 2x 49 W HB-NB
Eav = 302 lux
Load = 6.69 W/m2
TPS350 4x 80 W NB
Eav = 311 lux
Load = 8.2 W/m2
Eav = 302 lux
Load = 6.69 W/m2
Energy consumption
11
3.1.1 HID point sources

HPK380 1xHPI-P400W-BU SGR P-MB, aluminium reflector and glass cover
Luminaire arrangement
Rows: 4
Luminaires per row: 7
Distance (x,y): 8 m x 8 m
Mounting height: 17 m
32.00 m
Lighting results (MF: 0.7)

Load: 7.56 W/m = 2.64 W/m /100 lux
2
240
Work area: 316 lux
280
Uniformity: 0.75
280
280
320
320
320
LR
320
320
Surrounding area: 245 lux

Uniformity: 0.66
240
280
320
280
280
240
320
320
240
30.00
280
320
280
320
280
280
320
280
240
240
200
2.00
0.00
0.00
LENI
Lighting design criteria class: **
LENI current value: 30.2
LENI limit value: 83.7
12
56.00 m
3.1.2 Fluorescent line sources

TMX400 2xTL5 49W + GMX565 HB-NB
Rows: 3
Distance (x,y): 1.48 m x 10.5 m
32.00 m
280
240
Load: 6.69 W/m = 2.36 W/m /100 lux

2
320 320
320 320
320 320 320 320
280
Work area: 302 lux
280
30.00
LR
280
240
Uniformity: 0.77
320
320
280
Uniformity: 0.65
320
360
320
280
240
320
360
320
320
280
360
320
320 320
320 320
320
320
320 320
280
320
280
320
280
240
280
2.00
0.00
0.00
56.00 m
LENI
LENI
LENI current value (constant illum. and
daylight linking): 21.7
LENI limit value (constant illum. and
Adding lighting controls

Implementing constant illuminance system
lighting controls: LENI will drop 10%
Implementation of daylight linking system
lighting controls will cause LENI to drop by 10%
13
3.1.3 Fluorescent point sources

TPS350 4xTL5 80W NB
Rows: 3
240
Load: 8.20 W/m = 2.82 W/m /100 lux

2
32.00 m
280
280
Work area: 311 lux

320
Uniformity: 0.80
320
320

Uniformity: 0.69
280
320
280
240
320
320
320
320
320
240
30.00
280
280
280
320
320
280
240
280
2.00
0.00
0.00
LENI
LENI
14

Implementation of constant illuminance system lighting
controls will cause LENI to drop by 10%
Implementation of daylight linking system lighting
56.00 m
3.2 Industrial hall, height 12 m
LR
Room height: 12 m + 4 m roof

12 m height
Overview
Eav = 332 lux
Load = 6.33 W/m2
Light levels
Eav = 332 lux
Load = 6.33 W/m2
TPS350 4x 80 W MB
Eav = 314 lux
Load = 7.03 W/m2
TPS350 4x 80 W MB
Eav = 314 lux
Load = 7.03 W/m2
GPK380 1x 400 W P-MB
Eav = 300 lux
Load = 6.48 W/m2
Energy consumption
15

HPK380 1xHPI-P400W-BU SGR P-MB, aluminium reflector and glass cover
Rows: 3
32.00 m

240
Load: 6.48 W/m = 2.28 W/m /100 lux

2
280
280
280
30.00
280
Work area: 300 lux

Uniformity: 0.88
280

280
Uniformity: 0.66
320
320
320
320
320
320
320
320
320 320
320
320
320
320
280
240
280
280
240
240
280
2.00
0.00
0.00
LENI
16
56.00 m

TMX400 2xTL5 49W + GMX565 HB-NB
Rows: 3
Distance (x,y): 1.48 m x 11 m
32.00 m

Load: 6.33 W/m = 1.95 W/m /100 lux
2
210
280
Work area: 332 lux
350
350
420
280
Uniformity: 0.63
280 350
Uniformity: 0.50
420
280
350
350
350
280
280
280
350
350
420
420
350
280
280
350
420
350
420
350
420
280
350
350
350
280
280
350
280
350
350
350
350
350
280
280
350
350
350
420
350
30.00
280
280
210
280
420
420
280
350
350
280
280
210
2.00
0.00
0.00
56.00 m
LENI
LENI

17

TPS350 4xTL5 80W MB
Rows: 3
Distance (x,y): 4.75 m x 11 m
32.00 m

Load: 7.03 W/m = 2.44 W/m /100 lux
2
280
Work area: 314 lux

Uniformity: 0.75
280
280
320
320
280
320 320
320 320
320 320
320 320
320
320 320
280
Uniformity: 0.72
280
320
320
320
320 320
320 320
320 320
240
320 320
320
320
280
280
320
320
320
30.00
240
320 320
280
320 320
280
280
320
240
200
2.00
0.00
0.00
LENI
LENI
18

56.00 m
3.3 Industrial hall, height 7.5 m
Room height: 7.5 m + 4 m roof
7.5 m height
Overview
Light levels
HPK380 1x 400 W P-WB

Eav = 520 lux
Load = 10.8 W/m2
TMX400 2x 49 W HB-WB
Eav = 508 lux
Load = 8.44 W/m2
TMX400 2x 49 W HB-WB
Eav = 508 lux
Load = 8.44 W/m2
TPS350 4x 80 W MB
Eav = 500 lux
Load = 9.38 W/m2
TPS350 4x 80 W MB
Eav = 500 lux
Load = 9.38 W/m2
Energy consumption
19

HPK380 1xHPI-P400W-BU SGR P-WB, aluminium reflector and glass cover
Rows: 5
Distance (x,y): 7 m x 6.5 m
Mounting height: 6.5 m
32.00 m

2
Work area: 520 lux

Uniformity: 0.96
480
520
520
520
Uniformity: 0.74
520
520
520
520 520
520 520
520
520
520
520 520
520
480
520
520
520
520
520
520
480
520
520
520
520 520 520

520
30.00
480
480
480
Load: 10.8 W/m = 2.14 W/m /100 lux

2
520
520
520
520
520 520
520
520
480
520
520
520
480
480
520
480
2.00
0.00
0.00
LENI
20
56.00 m

TMX400 2xTL5 49W + GMX566 HB-WB
Rows: 4
32.00 m
30.00
Load: 8.44 W/m = 1.88 W/m /100 lux

2
Work area: 508 lux
400
320
400
Uniformity: 0.72
560
480
480
560
560
400
480
560
320
560
480
480
560
400
560
560
480
560
480
480
480
480
480
560
480
480
Uniformity: 0.55
400
480
480
480
560
560
560
480
480
400
560
400
560
480
320
400
480
480
560
480
480
560
480
400
480
320
400
2.00
0.00
0.00
56.00 m
LENI
LENI

21

TPS350 4xTL5 80W MB
Rows: 4
32.00 m

420
Load: 9.38 W/m = 2.00 W/m /100 lux

2
420
420
Uniformity: 0.89
540
540
480
480
480
420
540
480
480 480
420
420
480
480
540
540
480
480
480
480
480
Uniformity: 0.64
480 480 480
540
480
420
480
480
480
480
480
480 480
480
540
480
480
480
480
540
540
480
540
540
480
30.00
420
420
420
480
480
Work area: 500 lux
420
540
480
540
480
420
480
540
480 480
420
540
480 420
480
480
480
420
420
420
2.00
0.00
0.00
LENI
LENI
22

56.00 m
23
For more information:

www.philips.com/lighting
Data subject to change
Date: 11/2008
2008 Koninklijke Philips Electronics N.V.

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Industrial lighting

Application guide for general lighting.

Application guide Industrial lighting

Lighting design decisions

Lighting design examples

Industrial hall, height 12 m

Industrial hall, height 7.5 m

Application guide Industrial lighting

Point or line sources, fluorescent or HID?

High-intensity discharge lamps are used in narrow-

For general lighting in industry, two basic types of lighting

or wide-beam rotationally symmetrical luminaires,

2. Lighting solutions based on point light sources.

Application guide Industrial lighting

2 Lighting design decisions

General design considerations

consideration as well. All systems have typical features

Application guide Industrial lighting

2.1 Comparison: lighting

Fluorescent line sources

Fluorescent point sources

CDM point sources

HID point sources

Many moderate design

Lamp wattage range

Uniformity horizontal illuminance

Stronger than with line sources

3000, 3200, 4200 K

are preferred for point light sources in order to ensure

Colour temperature and colour rendering

Application guide Industrial lighting

The range of HID lamps is more limited. In addition, the

2.2 Comparison: installation

Fluorescent point sources

CDM point sources

HID point sources

Total cost of ownership

-10C< Tamb < 40C

-10C< Tamb < 40C

-20C< Tamb < 40C

-20C< Tamb < 40C

except TL5 TOP

except TL5 TOP

Number of luminaires / trunking system

dramatically reduced at above 50C . These lamps operate

Application guide Industrial lighting

2.3 Comparison: maintenance

Fluorescent point sources CDM point sources

HID point sources

Lumen output depreciation

Service lifetime (hours)

CDM-T /942 10000 h

(based on cycle of 12 hours,

Super 80 (HF) 17000 h

Super 80 (HF) 17000 h

SON Comfort 13000 h

Early failures and spot replacement

Application guide Industrial lighting

HPI Plus BU 10000 h

2.4 Decision scheme

Room and environmental characteristics

Very high mounting height (> 18 m)

Space is not climate controlled (e.g. outdoor)

Extreme ambient temperatures (e.g. cold stores, heat-generating industry)

2. Lighting solutions based on point light sources.