Production hall lighting: LED design and installation
In a production hall, lighting is not just about seeing, it affects productivity, quality and safety. Machining, assembly and inspection each need a different light level, and around moving machinery flicker-free, even light is the basis of safety. ProfiElekter designs, installs and documents production hall lighting as one accountable partner.
Production hall lighting affects productivity and safety
In a production hall lighting does more than just illuminate. The right light level and even light reduce defects and fatigue, speed up work and help prevent accidents around moving machinery. Different areas need different light: rough machining less, fine assembly and quality control considerably more.
Old fluorescent, metal-halide and sodium lamps give uneven light, flicker, run hot and restart slowly after a power cut. Flicker-free LED lighting solves these: even light with good colour rendering, instant start, lower energy use and a long maintenance-free lifetime. The decisive factor is the design, the fixture type, number and layout has to be calculated for the workstation and the task.
Production hall lighting is part of our wider industrial and office lighting service. We design, install and hand over the measurement reports needed for the use permit and audit.
Production lighting requirements: how many lux a production hall needs (EVS-EN 12464-1)
Every production area needs its own light level. The EVS-EN 12464-1 standard sets the lighting requirements for workplaces, and we design production lighting to it, by area and task: machining, assembly, inspection and the operator station. The table below gives typical target values; the exact solution comes from a lighting calculation.
| Production area / task | Illuminance Ēm (lux) | UGR (glare) | Ra (colour rendering) |
|---|---|---|---|
| Rough work, welding | 300 | 25 | 60 |
| General machining and assembly | 300 | 22 | 80 |
| Fine assembly | 500 | 19 | 80 |
| Precision work and inspection | 750 | 19 | 80 |
| Colour inspection, colour matching | 1000 | 16 | 90 |
| Control room, operator station | 500 | 19 | 80 |
| In-process storage and packing | 200 | 22 | 80 |
| Aisles and circulation | 150 | 25 | 40 |
Ēm is the maintained illuminance. Exact requirements depend on the current edition of EVS-EN 12464-1 and the nature of the work; we verify them in the lighting design.
Which luminaires suit a production hall
High-bay luminaire
High-output LED luminaire for tall production halls, even general lighting across the whole hall.
Line and linear luminaire
A continuous strip of light above production lines and workbenches, even light without shadows.
Flicker-free LED
Light without flicker, which avoids the stroboscopic effect on rotating machinery and reduces eye strain.
Task and precision lighting
Directed extra light at assembly, inspection and precision stations that need more lux.
IP65, ATEX and hygienic
Suitably rated luminaires for dusty, damp, explosive and food-industry rooms.
Design + measurement reports
Lighting calculations, as-built drawings and measurement reports for the use permit and audit.
The production-specific factors we account for
Flicker and the stroboscopic effect. Flickering light can make a rotating machine or tool appear to stand still, which is a serious accident risk. We use flicker-free LED drivers that eliminate the stroboscopic effect and also reduce eye strain over a shift.
Uniformity and shadows. Around moving machinery and workbenches the light has to be even, with no dark spots or hard shadows. We calculate the fixture layout so that workstations and walkways are lit evenly.
Colour rendering and inspection. In quality and colour inspection the colours have to be judged correctly. There we design for high colour rendering (Ra 90+) and a higher light level; for general production Ra 80 is enough.
Environment. Dust, welding fumes, moisture, chemicals and food hygiene place special demands on the fixture. We choose the protection rating (IP65 or higher), an ATEX certificate or a shatter-proof hygienic luminaire based on the site.
How production lighting saves energy
The biggest saving comes from replacing old lighting with efficient LED and from smart control. We split the lighting into general and task lighting, so the whole hall doesn't have to be kept at a high level when only the inspection and precision stations need it. In shift-based production, zone control switches unused lines and areas back down, which cuts energy use.
In the design we use lighting calculations (for example DIALux) to reach the required lux level with the smallest possible installed power. For example, in the Maardu port industrial lighting project energy use fell roughly 3 to 4 times, and even more with the automation.
Who production lighting is for
- Production and industrial companies that want even, safe light
- Metal, wood and plastics industries
- Food and packaging industries with hygiene requirements
- Assembly plants and manufacturing lines
- Developers and construction companies for new production buildings
The production lighting project process
Site survey
We review the hall: ceiling height, line and workstation layout, tasks and environment.
Lighting calculations
We calculate the illuminance level (lux) by area and task and select the fixtures.
Design and quote
We prepare the lighting design, an energy estimate and a clear quote.
Installation
We install the lighting in stages, without stopping production and with minimal downtime.
Measurements and handover
We carry out the measurements and hand over the reports and as-built drawings.
17+ years of experience with industrial and production sites
ProfiElekter has worked in technical building systems for over 17 years. We have upgraded lighting in industrial and production buildings, including the Maardu port area, where we replaced ~700 old fixtures with LED industrial fixtures. We are licensed to work independently and hold all the required qualifications.
Maardu port: ~700 fixtures, roughly 4× lower energy use
We upgraded the industrial lighting in the Maardu port area (~50,000 m²). We replaced ~700 old metal-halide fixtures (250–400 W) with 150 W LED industrial fixtures and added motion sensors and zone-based control. Energy use fell roughly 3–4 times, and even more with the automation. The large project was completed in about 1.5 months.
Production hall lighting, FAQ
It depends on the task. Rough work and welding around 300 lux, general machining and assembly around 300 lux, fine assembly 500 lux, precision work and inspection 750 lux, and colour inspection up to 1000 lux. The values come from EVS-EN 12464-1; we calculate the exact level from the workstation and the task.
Flicker-free lighting does not flicker imperceptibly to the eye. In production it is a safety issue: under flickering light a rotating machine or tool can appear to stand still (the stroboscopic effect), which is an accident risk. We choose flicker-free LED drivers, which also reduce eye strain over a shift.
For ordinary work Ra 80 is enough, but for colour and quality inspection, where colours must be judged correctly, we use Ra 90 or higher and up to 1000 lux. We design the inspection-area lighting specifically for that task.
Yes. For food production and washable rooms we install high-rated (for example IP65 or IP69K) and shatter-proof luminaires that withstand washdown, moisture and hygiene requirements. We choose the solution based on the room's requirements.
Yes. For explosive zones, for example certain chemical, wood-dust and paint areas, we install ATEX-certified luminaires. We choose the protection rating and zone class based on the site environment.
Yes. Where possible we work in stages on an operating site, line by line or zone by zone, so production can continue and downtime stays minimal. We agree the schedule before work begins.
It depends on the current lighting, the burning hours and the electricity price. Replacing old metal-halide and sodium lamps with LED and controls often reduces lighting energy use several times over. For example, in the Maardu port project energy use fell roughly 3 to 4 times. We calculate the payback from your site data.
See also
Industrial & office lighting
The full lighting service: production halls, commercial buildings, offices and car parks, from design to installation.
See the serviceWarehouse lighting
High-bay, rack-aisle and cold-store lighting for warehouses and logistics buildings.
See the serviceDocumentation & audit
Measurement reports, as-built drawings and the documentation required for the use permit.
See the serviceAsk for a production hall lighting quote
Describe your production hall, the tasks and the current lighting, and we'll explain how a lighting upgrade pays off and prepare a quote.