Factory LED Lighting Design: Complete Guide

Layout Plan

Effective factory LED lighting layout follows the zone-then-grid methodology: Step 1 — Divide the factory floor into functional zones (production, storage, QC, walkways) with distinct lighting requirements per EN 12464-1. Step 2 — For each zone, calculate required fixture count using the lumen method: N = (E x A) / (Phi x CU x LLF), where E = required lux, A = area in sqm, Phi = fixture lumens, CU = coefficient of utilization (typically 0.65-0.85 for high bays), LLF = light loss factor (0.80 for clean factories, 0.70 for dusty). A 1,000 sqm assembly area requiring 500 lux with 200W LED high bays (34,000 lumens, CU=0.80, LLF=0.75) needs approximately 25 fixtures. Step 3 — Arrange fixtures on a grid with spacing-to-mounting-height ratio (S/MH) <= 1.5 for UFO high bays. A 9m ceiling requires fixture spacing <= 13.5m for uniform coverage. Step 4 — Add task lighting at inspection/QC stations to achieve 750-1000 lux. Step 5 — Install occupancy/daylight sensors in storage zones with intermittent use (50-70% energy savings in these areas). A typical 10,000 sqm factory requires 120-200 LED high bay fixtures with total installed load of 24-60 kW, representing a 55-70% reduction from equivalent HID/Metal Halide installations (typically 70-120 kW).