4 Considerations for a Cost-effective Industrial Lighting Retrofit

Lighting accounts about 12% of total industrial electricity consumption, which is too high and unbelievable. The costly lighting promotes operators to search for ways to minimize the cost of lighting. Lighting retrofit is one of the popular way to achieve their goal. However, unlike home lighting retrofit, industrial lighting retrofit is more complex and difficult to manage. It is of high risk to retrofit lighting without any preparation and consultation. Most operators have little thought of lighting retrofit. Some of them are unclear for their goals of lighting retrofit, but imagine a new and high performance lighting system. A successful lighting retrofit may requires professional electricians, energy service company, and lighting manufacturer. For operators, profits always ranks the first. Therefore, a cost-effective industrial lighting retrofit makes more sense.

What is the Goal for Lighting Retrofit

When it comes to industrial lighting retrofit, operators are supposed to identify their goals. Only knowing their goals of lighting retrofit clearly can they carry out the further actions favorably. Goals of lighting retrofit may include energy savings, improving light quality, increasing productivity, reducing maintenance, protecting environment, etc. Clear goals can influence the needs and functions of lighting system. If operators want to save energy, a dimmable and intelligent controlled lighting system can meet the need. If operators would like to increase productivity, a lighting system with sufficient but not dazzling lighting can works. Operators may have various goals but they have to order the priority of them due to the budget limitation. A cost-effective lighting retrofits is capable of cutting off 40% of electricity bill while only pay for itself no more than 5 years. However, most paybacks of lighting retrofits occur in less than 3 years. Improper lighting retrofit just result a waste of money and undesired lighting effects. Therefore, without determinate goal, lighting retrofit is worthless.

When Lighting Retrofits Make Sense

Definitions of worthy lighting retrofit are varied. Lighting retrofits make sense when they are cost-effective or at least meet specific needs. However, lighting retrofits are unnecessarily in any occasions. They are valuable in certain conditions, including insufficient light, excessive lasting hours, high energy cost, inefficient lighting effects, poor maintenance, etc. Insufficient light are threatening to safety and security, replacing the lamp or luminaire to higher output can make sense. Excessive lighting hours wastes energy and money, adding intelligent controls can save energy effectively. High energy cost are related with efficient light sources and lighting control system. All these factors should be taken into account during lighting retrofits. Poor maintenance may be resulted by excessive working life of the lamp. Replacing the lamp or luminaire is helpful for easier maintenance.

Which Light Source Should Be Selected

Generally speaking, LED is the optimum option for lighting retrofits. LEDs have longer lasting life times and consume up to 80% less energy than traditional halogen light source while producing same amount of light. There is a table of the comparison of the main characteristics between incandescent, halogen, fluorescent and LED.

Lamp Type	Incandescent	Halogen	Fluorescent	LED
CCT(K)	2700	2700-3500	2700-8000	2700-8000
Efficacy (Lm/W)	6-16	16-30	70-120	80-160
Lifetime(hours)	1000	1000-3000	15000-45000	50000
Application	Indoor, outdoor	Indoor	Indoor	Indoor, outdoor
Additional Info	High IR radiation	High IR radiation	High UV radiation	Little UV and IR radiation
Hazardous Chemical Content	No	Halogens	Mercury, Neon	No
Starting Time (to full output)	Slow	Slow	Fast to instant	Instant

 

From the table, we can know that LEDs are better than traditional light sources in certain factors.

• LEDs have wide CCT (correlated color temperature) range. Different color temperature brings various feeling and atmosphere.
• LEDs have higher efficacy than traditional lamps, which means LED can emit more light with the same power consumed. The total cost of LEDs is very low compared to other conventional light sources. Choosing LEDs can help you save money.
• LEDs can lasting up to 500,000 hours, significantly longer than other traditional light sources. LEDs are durable as they are just slowly lose their light output over the time. 
• LEDs can not only apply for indoor but also outdoor. Some of them are equipped with outstanding waterproof, dust-proof and corrosion resistance ability.
• LEDs emit light with little UV (ultraviolet) and IR (infrared) radiation, which makes them widely used for the goods that are sensitive to heat and the materials subject to UV degradation.
• LEDs are environmental friendly because they are free of hazardous chemical content, such as halogens, mercury and neon. They are also more safer to users without hazardous chemical content.
• Unlike other traditional lamps, LEDs turn on instantly, no waiting around to warm up, reaching full brightness rapidly.

Lamp Retrofit, Retrofit Kits, or Luminaire Replacement  

LEDs are the optimal selection of lighting retrofits. There are three common retrofit options, lamp retrofit, retrofit kit, and luminaire replacement. It is confusing about the difference between three options. Classifying lamp and luminaire is the first step for better understanding. In simple words, a luminaire is the combination of a lamp and a fixture. Details of the three retrofit options are as followed:

Lamp Retrofit

Lamp retrofit is only adapted to retrofitting fluorescent fixtures with tubular LEDs. Lamp retrofit is less expensive and easier compared to other retrofits. This retrofit is implemented by directly replacing lamp, removing ballast, or adding driver and LED tube.

Direct lamp replacement

This method removes the lamp only while still maintaining existing ballast and sockets. It is the easiest and lowest cost of all retrofits. But ballast incompatibility and poor maintenance may occur. Furthermore, it is not dimming with old ballast.

Remove ballast

Existing ballast is removed in this retrofit. More energy is saved and it is also of quick installation. However, it requires electrician for safe replacement. Dimming function cannot be realized until ballast is replaced.

External driver & LED tube

It is the most efficient way of lamp retrofit. External driver provides an opportunity for dimming capabilities and better thermal management. The drawbacks of this method include electrician requirements and high cost.

Retrofit Kits

Replacing LED retrofit kits is more efficient than lamp retrofits. LED retrofit kit is particularly used when there is a need to remain existing housing or the housing is difficult to remove. LED retrofit kits are composed of LED fixture, ballast, socket and electronics. Since the functional parts of illumination are replaced to the new, longer lifespan is accessible. Additionally, lighting control and better thermal management are also available. Thus, LED retrofit kits can save as much as 50% energy consumption. However, retrofit kits are of higher cost than lamp retrofit and electricians are needed for replacement.

Luminaire Replacement

Luminaire replacement is the most expensive but efficient retrofit option. This retrofit method replaces existing luminaires to new LED luminaires. New LED luminaires bring maximum longevity, energy saving, safety, visual effects, controllability, maintenance, and light quality. Luminaire replacement costs more time than other two retrofits. As we all know, LEDs are the efficient, performing high output with less energy consumption. But this benefit be a risk of over-lighting for existing space by one-one replacement, resulting uncomfortable lighting experience. It says without doing that luminaire replacement is the most expensive retrofit. However, economic analysis cannot be calculated by cost alone. Paybacks like the saved energy, increased satisfaction, and improved productivity should also be taken into account. Once the benefits of retrofit occur, the expense is worthy. Though initial cost of luminaire replacement is high, incremental cost will decreased with the long lifespan. Choosing the right lighting manufacturers is critical for ensuring the quality and longevity of lighting system. AGC is a leading industrial and commercial LED lighting manufacturer. Here are some options for luminaire replacement.

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