What is warehouse lighting?

     Table of contents

1. What is warehouse lighting?
2. What are the different types of warehouse lighting?
3. What are the prices of different types of warehouse lighting fixtures?
   
4. How to choose the right lighting fixture for the warehouse?
   
5. What are the factors that affect the price of warehouse lighting fixtures?
   
6. What is the general service life of warehouse lighting fixtures?
   
7. How to choose a reliable brand when purchasing warehouse lighting fixtures?
   
8. How to judge the quality of warehouse lighting fixtures?
   
9. How does the material process of warehouse lighting fixtures affect the quality of the fixtures?
   
10. What are the advantages and disadvantages of aluminum alloy and stainless steel shells?
    
11. Does the shape of the shell of warehouse lighting fixtures affect heat dissipation?
    
12. FAQ for warehouse lighting fixtures
13. Conclusion

What is warehouse lighting?

Warehouse lighting refers to the system and solution that provides a lighting environment that meets the requirements of brightness, uniformity, color rendering, etc. for the daily operation of the warehouse (such as cargo storage, sorting, handling, inventory, loading and unloading, etc.) by manually setting up lighting equipment in the warehouse (including storage areas, operation areas, passages, loading and unloading areas, etc.).

It is not a simple "installation of lamps", but it needs to combine factors such as the warehouse structure (floor height, shelf layout), the type of stored goods (whether it is flammable and explosive, whether it needs fine identification), and the operation mode (manual operation, mechanical automation) to design a lighting system that can meet the needs of safety and efficiency while taking energy saving into account.

The core role of warehouse lighting

Ensure operational safety

Avoid collisions caused by insufficient light (such as forklifts and shelves, personnel and equipment), cargo damage (such as misoperation) or personnel injuries (such as tripping, falling).

For warehouses storing dangerous goods, explosion-proof and high-temperature-proof lighting equipment can reduce safety hazards.

Improve work efficiency

Sufficient and uniform light can help staff quickly identify cargo labels and specifications, and reduce the error rate of sorting and inventory.

Mechanical operations (such as automated shelves, AGV robots) require stable lighting and sensors to operate accurately.

Protect goods and facilities

Some special goods (such as food and medicine) have requirements for the "color temperature and ultraviolet content" of lighting to avoid deterioration due to improper lighting (such as oxidation and mildew caused by light).

Appropriate lighting can reduce equipment losses caused by line of sight problems (such as collision and deformation of shelves).

Key design elements of warehouse lighting

Brightness requirements (illuminance)

Different areas have different requirements for brightness, and need to be divided according to the intensity of work:

• Storage area (only occasionally pick up goods): 50-100 lux;
• Sorting area, inventory area (fine operation): 200-500 lux;
• Loading and unloading area, channel: 100-200 lux;
• Office area (such as warehouse duty room): 300-500 lux.

Lighting uniformity

Avoid local darkness or brightness (such as shelf shadow area), otherwise it is easy to cause visual fatigue or miss details. Usually the "ratio of minimum illumination to average illumination ≥ 0.7" is required.

Color rendering index (Ra)

Refers to the ability of light to restore the true color of an object (Ra value 0-100). For areas where the color of goods and labels needs, to be identified (such as clothing and electronic component warehouses), Ra should be ≥ 80; for ordinary storage areas, Ra ≥ 60 is sufficient.

Energy saving and durability

Warehouse lighting usually lasts for a long time (some operate 24 hours a day), so energy-saving lamps (such as LED lamps, which consume only 1/5 of the energy of traditional incandescent lamps) should be given priority, and the life of the lamps should be considered (LED life can reach more than 50,000 hours, reducing replacement costs).

Adaptation to the warehouse environment

High-shelf warehouses: "deep-lighting lamps" or "track lights" are required to ensure that the light can reach the bottom of the shelf;

Wet/dusty warehouses: Choose lamps with waterproof and dustproof grades (IP65 and above);

Low-temperature warehouses (such as cold chains): lamps need to adapt to low-temperature environments such as -20℃ to avoid startup failures.

Common warehouse lighting fixture types

Lamp Type	Features	Applicable scenarios
LED mining lamp	High brightness, energy saving, long life, dimming available	Large warehouses, racking areas, loading and unloading areas
LED flood light	Directional irradiation, concentrated light	Large open areas (such as flat storage areas)
LED Track Lights	Flexible adjustment of the irradiation direction	Shelf aisles, temporary work areas
Explosion-proof lamps	Anti-spark, high temperature resistance	Dangerous goods warehouse (such as chemicals, oil and gas)

 

What are the different types of warehouse lighting?

The types of warehouse lighting can be divided according to the function of the lamp, installation method, applicable scenarios and other dimensions. Different types correspond to different warehouse needs (such as floor height, work intensity, and cargo characteristics). The following are common classifications and characteristics:

Classification by lamp function and light source type (core classification)

This is the most commonly used classification method, which is directly related to lighting effects, energy saving and adaptation scenarios.

1. LED mining lamp (mainstream choice)

Core characteristics:

The light source is LED, and the energy consumption is only 1/3 of the traditional metal halide lamp, and the life span can reach 50,000-100,000 hours (reducing the frequency of replacement);

High brightness (single lamp power 50W-200W), wide irradiation range, and the light angle can be adjusted by lens (spotlight or floodlight);

Support dimming and intelligent sensing (such as radar sensing, automatically turn on the light when people/vehicles pass by, and turn off when idle).

Applicable scenarios:

High and large warehouses (floor height above 5 meters), shelf areas (especially high-rise shelves, where light needs to penetrate the shelves);

General storage areas, loading and unloading areas and other large areas.

Advantages: With the best comprehensive energy saving and durability, it is the first choice for modern warehouses.

2. LED floodlight

Core features:

The light is projected in a directional manner (similar to the focus of a "flashlight"), and the irradiation angle can be adjusted (30°-120°).

Suitable for local enhanced lighting;

High waterproof and dustproof level (IP65 and above), suitable for humid and dusty environments.

Applicable scenarios:

Warehouse entrances and exits, loading and unloading platforms (need to illuminate the truck loading and unloading area);

Temporary operation areas (such as temporary stacking points), and the bottom shadow area of the shelf (supplementary lighting).

3. LED track lights

Core features:.

The lamps are installed on the track, which can be flexibly moved and rotated, and the irradiation direction can be adjusted conveniently;

The power of a single lamp is relatively small (20W-50W), which is suitable for local fine lighting.

Applicable scenarios:

Sorting area, inventory counter (need to focus on the cargo label);

Shelf channel (the position can be adjusted with the shelf), and flexible layout area of small warehouses.

4. Explosion-proof lamps

Core features:

Explosion-proof housing and spark-proof design are used to prevent explosions caused by high temperatures or arcs generated during lamp operation;

The light source is mostly LED (safe and energy-saving), and some special models are corrosion-resistant.

Applicable scenarios:

Hazardous goods warehouses (such as areas storing chemical raw materials, flammable and explosive goods, and oil and gas tanks);

Warehouses with a lot of dust (such as grain and plastic granule warehouses to prevent dust from igniting at high temperatures).

5. Traditional light source lamps (gradually eliminated)

Metal halide lamps/sodium lamps: They were once used for their high brightness, but they consume a lot of energy (3 times that of LEDs at the same brightness), have a short lifespan (only about 10,000 hours), and are slow to start (need to be preheated). They are only still available in old warehouses.

Incandescent lamps/fluorescent lamps: They have low brightness and high heat generation. They are almost never used in modern warehouses and may only be used temporarily in small areas such as duty rooms.

Classification by installation and illumination method

1. Top fixed lighting

Installation method: The lamp is fixed on the warehouse ceiling or top steel frame and illuminates vertically downward.

Features: Wide coverage, suitable for large areas (such as overall storage areas), but lamps need to be selected according to the floor height (the higher the floor height, the deeper the lamp is needed to avoid light attenuation).

Representative lamps: LED mining lamps, high ceiling lamps.

2. Track lighting

Installation method: The lamp is fixed on the top of the shelf or above the channel through a slide rail, and can be moved along the track and adjusted in angle.

Features: Strong flexibility, can dynamically adjust the lighting according to the shelf gap and operation line, and reduce shadows.

Applicable scenarios: Sorting areas with dense shelves, multi-category cargo storage areas.

3. Wall-mounted lighting

Installation method: The lamp is fixed on the warehouse wall or the side of the shelf, and illuminates horizontally.

Features: Supplement the lack of top lighting and illuminate the "top light blind spots" such as corners and channel edges.

Applicable scenarios: low warehouses, both sides of the passage, and the walls of the loading and unloading area.

4. Mobile lighting

Installation method: The lamp is equipped with a bracket or rollers and can be moved freely (such as a portable lamp, an emergency lamp).

Features: It is used for temporary operations (such as emergency inventory at night), fault repair or emergency lighting during power outages.

Note: Mobile lamps must meet safety standards (such as explosion-proof mobile lamps for hazardous goods warehouses).

Classification by applicable scenarios and special needs

1. Conventional warehouse lighting

Applicable scenarios: ordinary cargo warehouses (such as daily necessities, hardware), without special environmental requirements.

Core needs: meet basic illumination (50-200Lux) and energy saving, and LED industrial and mining lamps are preferred.

2. Fine work lighting

Applicable scenarios: sorting area, inventory area, packaging area (label identification and inspection of cargo details are required).
Core requirements: high illumination (200-500Lux), high color rendering index (Ra≥80, restore the true color of the goods), commonly used track lights + local spotlights.

3. Explosion-proof lighting

Applicable scenarios: dangerous goods warehouses (chemicals, oil and gas, flammable and explosive goods), dust warehouses (flour, metal powder).

Core requirements: lamps must pass explosion-proof certification (such as Ex dⅡCT4) to avoid electric sparks or high temperatures, and explosion-proof LED lamps are commonly used.

4. Low-temperature environment lighting

Applicable scenarios: cold chain warehouses (such as frozen food and pharmaceutical cold storage, the temperature may be as low as - 30℃).
Core requirements: lamps must be resistant to low temperatures (to avoid freezing and cracking of components), stable startup (brightness is not affected at low temperatures), and special low-temperature LED lamps are the first choice.

5. Emergency lighting

Function: Automatically start in the event of a sudden power outage to ensure personnel evacuation and temporary lighting of key areas (such as safety passages and emergency exits).

Requirements: A backup power supply (battery) is required, the continuous lighting time is ≥90 minutes, and the lamps must have obvious emergency signs.

Summary: How to choose the type of warehouse lighting?

Priority light source: LED is the only recommendation (energy-saving, durable, and highly adaptable), and traditional light sources are eliminated;

Choose lamps based on the scene:

Large warehouses → LED mining lamps (fixed on the top);

Dense shelves → track lights (flexible fill light);

Dangerous goods / cold chain → special explosion-proof / low-temperature LED lights;

Fine work → high color rendering track lights + spotlights.

Reasonable matching of different types of lighting can not only meet the needs of each area, but also avoid energy waste caused by "over-lighting".

What are the prices of different types of warehouse lighting fixtures?

The prices of different types of warehouse lighting fixtures vary depending on factors such as brand, power, material, and function. The following is a reference to the price range of some common types of lamps:

LED mining lamp: This is a common type of lamp used in warehouse lighting. The price of a 50W LED mining lamp is about 50-500 yuan; the price of a 100W one is usually between 100-300 yuan; the price of a 200W one is generally between 150-1000 yuan. For example, the price of Shanghai Yaming's 200W LED mining lamp is 18.8 yuan, and the price of Philips LED high-ceiling mining lamp BY698P is 2200 yuan.

LED floodlights: The price is relatively affordable. The price of a 50W LED floodlight is generally around 10-100 yuan, such as the cross-border LED square floodlight outdoor waterproof model, which costs 18.9 yuan; the price of floodlights with a power of 100W and above may be between 100-500 yuan, such as the solar LED floodlight outdoor waterproof strong light model, which costs 55 yuan for 100W.

LED track lights: The price of track lights varies greatly. The price of a single LED track light with a power of 20W-50W may be around 50-500 yuan. The specific price depends on the brand, quality, and type of lamp, as well as the length and material of the track.

Explosion-proof lamps: The price of explosion-proof lamps varies depending on the explosion-proof level and power. Generally speaking, the price of explosion-proof LED lamps with ordinary power (such as 30W-100W) is around 10-500 yuan, for example, the price of 100W LED explosion-proof mining lamps for Yaming warehouse workshop is 18.8 yuan; while some high-explosion-proof grade and high-power explosion-proof lamps may cost more than 500 yuan, such as TCD510 explosion-proof lamps, which cost 99 yuan, and LED explosion-proof lamps, gas station lamps, warehouse workshop explosion-proof lamps, high-power models, which cost 500 yuan.

Special environment lamps: such as low-temperature LED lamps used in cold chain warehouses, are relatively expensive, and the price of Owen CE-certified IP65 waterproof and dustproof cold storage lamps is 170 yuan/piece.

How to choose the right lighting fixture for the warehouse?

Choosing lighting fixtures suitable for warehouses requires comprehensive judgment based on the functional characteristics of the warehouse, environmental conditions, lighting needs, cost budget and other factors. The following are specific selection methods and key considerations:

1. Clarify the core needs of the warehouse: First clarify the "lighting scenario"

Different types of warehouses have very different requirements for lighting fixtures. First, the core attributes of the warehouse must be clarified:

Storage type

General cargo warehouses (such as daily necessities, packaged foods): have high requirements for lighting uniformity and basic brightness, and no special environmental restrictions.

Special cargo warehouses:

Dangerous goods/explosion-proof warehouses (such as chemicals, flammable and explosive goods): must choose explosion-proof lamps (by the explosion-proof level, such as Ex dⅡC T4) to avoid dangers caused by electric sparks.

Cold chain warehouses (such as cold storage and freezers): need to choose low-temperature special lamps (resistant to low temperatures of -20℃~-40℃, waterproof and fog-proof, to avoid frost affecting lighting).

Precision instruments/electronic warehouses: need to avoid glare and strobe, and can choose anti-glare LED lights to prevent direct light from interfering with equipment or personnel operations.

Operation scenario

Pure storage warehouse (only goods are stacked, with few personnel activities): Prioritize "high brightness + low energy consumption", and there is no need to excessively pursue color rendering (Ra≥60).

Picking/sorting warehouse (frequent operation by personnel): high color rendering (Ra≥80, can clearly distinguish the color and label of goods), low glare (UGR≤22, to avoid eye fatigue), and uniform lighting (no obvious shadows).

Tall shelf warehouse (layer height above 5 meters): It is necessary to select high projection distance lamps (such as LED mining lamps, high ceiling lamps) to ensure that the bottom layer of the shelf can also be illuminated (avoid bright upper layer and dark lower layer).

2. Key parameters: Use "data" to lock lamp performance

Brightness and illumination: meet basic lighting needs

Illuminance (unit: lux) is the core indicator and needs to be determined according to the intensity of warehouse operations:

Pure storage area: 100~200 lux (can see the location of goods clearly).

Picking/sorting area: 300~500 lux (labels and operation details must be clearly identified).

Passage/entrance and exit: 200~300 lux (to ensure the safety of personnel walking).

Note when choosing: the power of the lamp must match the height of the warehouse - 100~200W LED lamps can be selected for floor heights of 5~10 meters, and 200~400W high-power lamps are required for floor heights above 10 meters, or a focusing lens is used to enhance the projection ability.

Light source type: LED is preferred, and subdivided categories are selected as needed

At present, warehouse lighting has basically eliminated traditional incandescent lamps and fluorescent lamps. LED is the mainstream choice (energy consumption is only 1/10 of incandescent lamps, and the life span is more than 50,000 hours). The specific subdivision type is selected as needed:

LED mining lamp: suitable for tall warehouses (floor height above 5 meters), large luminous angle (60°~120°), wide lighting coverage, and high cost performance (suitable for ordinary cargo warehouses).

LED floodlights: Strong focusing (lighting angle 30°~60°), suitable for local key lighting (such as specific areas of shelves, entrances and exits), can be used with industrial and mining lamps to supplement local brightness.

LED track lights: Suitable for small and medium-sized warehouses or areas with dense shelves, can flexibly adjust the irradiation direction (such as moving tracks to different shelves), suitable for scenes where storage locations are frequently adjusted.

Explosion-proof LED lights: Only used in explosion-proof warehouses, it is necessary to confirm the explosion-proof level (such as "Ex" at the beginning) and protection level (above IP65, dustproof and waterproof).

Energy saving and durability: Reduce long-term costs

Energy consumption: Choose high-efficiency lamps (light efficiency ≥100lm/W, brighter and more energy-saving at the same power), and use intelligent control (such as human body sensing, light sensing switch, and lights off when people leave) to save energy.

Lifespan: Give priority to chip brands (such as Philips, Osram) and lamps with good heat dissipation design (aluminum alloy shell, fin heat dissipation) to avoid frequent replacement (warehouse lamps are installed at high locations and replacement costs are high).

Protection level: Warehouses are dusty and may be humid, so IP54 or above is required (dustproof and splashproof); humid or cold chain warehouses require IP65 (completely dustproof and low-pressure water sprayproof).

3. Environmental adaptation: avoid "lamp incompatibility with the environment"

Floor height and installation method

Floor height ≤ 5 meters: ceiling-mounted LED flat panel lights and suspended mining lamps (short booms) can be selected, which are easy to install and have uniform lighting.

Floor height > 5 meters: Suspended high-power lamps must be used (long booms or chains to reduce the irradiation height) to avoid light being blocked by shelves, resulting in dim bottom floors.

Space layout

Shelf-dense areas: select "wide beam angle lamps" (120°) to reduce shelf shadows; or add track lights between shelves to illuminate aisles and cargo locations in a targeted manner.

Open and spacious areas (such as bulk cargo storage areas): use "high-power mining lamps" for centralized lighting, taking into account coverage and brightness.

Power supply and wiring

Old warehouse: If the circuit load is limited, low-power LED lamps are preferred (to avoid tripping); new warehouses can reserve three-phase electricity to adapt to high-power lamps.

4. Cost balance: Don't blindly pursue "expensive", but don't be greedy for "cheap"

Initial investment vs long-term cost

Ordinary warehouse: Give priority to cost-effective domestic LED mining lamps (such as 100W about 100~300 yuan). Although the unit price is low, the light efficiency and lifespan meet the standards (50,000 hours), and the long-term electricity fee + maintenance fee is lower.

Special warehouse: "Function priority" such as explosion-proof lamps and low-temperature lamps. Even if the unit price is high (such as explosion-proof lamps 100W about 300~800 yuan), they must meet safety standards to avoid later risks.

Brand selection

Sufficient budget: Choose international brands (such as Philips, Osram) or domestic first-line brands (such as Foshan Lighting, Sanxiong Aurora), stable quality, guaranteed after-sales service (suitable for large warehouses with long-term use).

Limited budget: Choose domestic second-tier brands, focus on "chip + heat dissipation" (such as clearly marked "Taiwan Jingyuan chip" and "all-aluminum heat dissipation"), and avoid unbranded low-priced and low-quality lamps (the light decays quickly and becomes dim in 1 year).

What are the factors that affect the price of warehouse lighting fixtures?

The factors affecting the price of warehouse lighting fixtures are mainly as follows:

Type and function of lighting fixtures: Different types of warehouse lighting fixtures have special functions and application scenarios, and the prices vary significantly. For example, the price of ordinary 100W LED mining lamps is usually between 50-300 yuan, while the price of 100W LED explosion-proof lamps is 1500-6000 yuan due to the need to meet explosion-proof requirements, which is 2-10 times that of ordinary lamps.

Power size: Generally speaking, the greater the power, the stronger the lighting effect, and the higher the price. For example, the price of a 50W mining lamp and a 100W mining lamp may differ by tens or even hundreds of yuan; the price of a linear lamp of about 10W is generally between 40-60 yuan, and that of a 20W lamp may reach 70-100 yuan.

Brand factors: Well-known brands usually invest more in R&D, production and quality control, and their product prices are relatively high, but they can provide more stable performance and high-quality after-sales service. For example, the price of some internationally renowned brands of industrial and mining lamps may be hundreds or even thousands of yuan, while the price of a 100W industrial and mining lamp of an ordinary brand may be between 100-200 yuan.

Material cost: The price will vary depending on the material of the lamp shell, transparent cover and other materials. For example, the explosion-proof lamp uses a high-strength die-cast aluminum alloy shell and is anti-corrosion treated, and the transparent cover uses high borosilicate tempered glass, which is more expensive; while ordinary lamps are mostly plastic or ordinary aluminum, and the transparent cover is ordinary glass, which is less expensive.

Technical and performance parameters: The protection level, light efficiency, color rendering index and other parameters of the lamp will also affect its price. Industrial and mining lamps with high protection level, good light efficiency and high color rendering index have relatively high manufacturing costs, and the price will also rise accordingly. For example, the price of anti-glare, flicker-free and high color rendering (Ra≥80) lamps used in precision instruments or electronic warehouses will be higher than that of ordinary warehouse lighting lamps.

Core component quality: The difference in core components such as light source chips and driver power supplies will lead to price differences. High-end explosion-proof lamps use imported lamp beads from Philips, Cree, etc., equipped with constant current and constant voltage waterproof power supplies, and are more expensive; while ordinary lamps mostly use domestic chips, equipped with simple drivers, and are cheaper.

Market supply and demand relationship: In the peak season, the supply of warehouse lighting fixtures is relatively tight, and prices may rise; in the off-season, prices may be relatively stable or even have certain discounts.

Customized needs: If you need to customize the lighting length, light distribution control, color temperature personalized adjustment and other functions of the lamp, the price will be higher than the standard model. For example, industrial line lights can customize the lighting length and light distribution control, and the customization fee can be up to 1.5 times that of the standard model.

What is the general service life of warehouse lighting fixtures?

The service life of warehouse lighting fixtures is affected by factors such as the type, quality, use environment, and maintenance of the fixtures. There are large differences. Generally, it can be divided into theoretical service life (under laboratory conditions) and actual service life (in actual applications). The following is an analysis of the service life and influencing factors of common types of warehouse lighting fixtures:

Service life of common warehouse lighting fixtures

1. LED lamps (mainstream choice)

Theoretical service life: usually marked as 50,000-100,000 hours (calculated based on 12 hours of use per day, about 11-23 years).

This is based on the test results under ideal conditions such as constant temperature, constant pressure, and no dust/humidity in the laboratory. The core basis is the light decay speed of the LED chip (when the luminous flux decays to 70% of the initial value, it is considered the "end of life").

Actual service life: generally 20,000-50,000 hours (about 4.6-11 years).

LED mining lamps, LED ceiling lamps, LED linear lamps, etc. commonly used in warehouses may have actual lifespans shorter than the theoretical values due to voltage fluctuations, dust accumulation, and high temperature environments (such as the top of the warehouse in summer).

2. Traditional gas discharge lamps (gradually phased out)

Metal halide lamps/high-pressure sodium lamps:

Theoretical lifespan: about 10,000-20,000 hours (calculated at 12 hours per day, about 23,000-46 years).

Actual lifespan: about 5,000-15,000 hours (about 12,000-34 years).

Due to the principle of light emission (arc discharge), the filament of this type of lamp is easily worn out, and frequent starting (such as frequent switching of lights in warehouses) will greatly shorten the lifespan; in addition, its accessories such as ballasts and triggers have a short lifespan (about 8,000 hours) and may be damaged before the light source.

3. Special function lamps (explosion-proof lamps, moisture-proof lamps, etc.)

Theoretical life: close to ordinary lamps of the same type (such as the theoretical life of LED explosion-proof lamps is 50,000-80,000 hours).

Actual life: about 30,000-60,000 hours (about 7-14 years).

This type of lamp has a strong sealing shell (high protection level, such as IP65/IP66), and the heat dissipation conditions may be slightly worse, but the material and process are more durable (such as die-cast aluminum shell, anti-corrosion treatment). If properly maintained, the life may be longer than ordinary LED lamps.

Key factors affecting the service life of warehouse lighting lamps

1. Lamp quality and core components

Light source and driver power supply: The core of LED lamps is the chip (such as Cree, Philips and other imported chips with slow light decay) and the driver power supply (constant current drive is more stable than constant voltage drive, and the life is more than 30% longer). Poor quality drivers are easily burned due to voltage fluctuations, which directly leads to the scrapping of lamps.

Material and craftsmanship: The heat dissipation of the shell (such as aluminum heats better than plastic) and sealing performance (low dust and water resistance, dust/water vapor entering will accelerate the aging of internal components) directly affect the life. For example, in a logistics warehouse with a lot of dust, if the protection level of the lamp is lower than IP54, it may be damaged by internal dust accumulation and short circuit in 1-2 years.

2. Use environment

Temperature: The temperature on the top of the warehouse may reach 40-50℃ in summer, and the light decay of LED lamps will accelerate at high temperatures (the life may be shortened by 20% for every 10℃ increase in temperature); while low temperature environments (such as cold chain warehouses) may affect the stability of the driving power supply.

Humidity and corrosiveness: In humid warehouses (such as agricultural product warehouses) or warehouses with corrosive gases (such as chemical warehouses), if the lamps are not designed to be anti-corrosive and moisture-proof, metal parts are prone to rust and circuits are prone to short circuits.

Dust and vibration: In warehouses with a lot of dust (such as building materials warehouses), if the lamps are poorly sealed, dust accumulation will block the light source and hinder heat dissipation; in warehouses with frequent vibrations such as forklifts, if the lamps are not installed firmly or the internal components are loose, they may be damaged in advance.

3. Usage and maintenance habits

Switching frequency: Frequent switching will cause instantaneous current shock to the lamps. LED lamps are less affected, but the filaments of traditional gas discharge lamps (such as metal halide lamps) are prone to breakage due to alternating hot and cold, greatly shortening their lifespan.

Cleaning and maintenance: Regularly clean the dust on the surface of the lamp (especially the heat dissipation holes) and check the line connection (to avoid heat caused by poor contact) to extend the lifespan. For example, if the LED lamp is not cleaned for a long time, the heat dissipation efficiency will decrease, and obvious light decay may occur in 3 years, while regular maintenance can extend it to more than 5 years.

Power supply stability: The voltage in the warehouse fluctuates greatly (such as caused by the start and stop of large equipment). If a voltage regulator is not equipped, the driving power supply is easily damaged.

Suggestions for extending the life of warehouse lighting fixtures

Prefer high-quality LED lamps: Look for well-known brands (such as OPPLE, NVC's industrial series, or professional industrial lighting brands), ensure the quality of core components (chips, drivers), and the protection level is at least IP54 (IP65 for warehouses with a lot of dust).

Match the use environment: cold chain warehouses choose low-temperature adaptive lamps, explosion-proof warehouses must use explosion-proof certified lamps, and humid warehouses choose moisture-proof and anti-corrosion models.

Standardized installation and maintenance: The lamps are installed firmly (anti-vibration) and heat dissipation space is reserved; clean dust regularly (every 3-6 months), check the circuit and drive power supply.

Stable power supply: Install a voltage stabilizer in warehouses with large voltage fluctuations to prevent the lamps from being in an overvoltage state for a long time.

In short, the actual service life of warehouse lighting fixtures is the longest for LED lamps (20,000-50,000 hours), and traditional lamps are shorter (5,000-15,000 hours), and are greatly affected by the environment and maintenance. Choosing high-quality lamps that adapt to the environment and doing a good job of maintenance is the key to extending the life.

How to choose a reliable brand when purchasing warehouse lighting fixtures?

When purchasing warehouse lighting fixtures, you can choose a reliable brand from the following aspects:

Check brand certification and qualifications: Certification is an important basis for measuring whether brand products meet standards. For example, fixed lamps such as mining lamps must have CCC certification, and explosion-proof lamps need explosion-proof certificates. In addition, if the company has ISO9001 quality management system certification, it means that its production process is more standardized and the product quality is more guaranteed.

Understand the brand market reputation: Understand the brand's market performance and user satisfaction by consulting relevant materials, consulting professionals, or checking user reviews. For example, in some industrial lighting forums or related industry exchange groups, ask other users about their experience and evaluation of certain brands.

Consider product performance and quality: High-quality brand lamps perform well in performance. You can pay attention to the power factor of the lamp. The power factor of good products is basically greater than 0.95, while low-end products may be around 0.5. At the same time, confirm the brand of the lamp beads. Brands such as Philips and Osram are more common and reliable in quality. In addition, the heat dissipation material of the lamp is also critical. It is mainly made of aluminum. The heat dissipation effect of die-cast aluminum is usually better than that of profile aluminum.

Evaluate the quality of after-sales service: Warehouse lighting lamps may fail during use, so the brand's after-sales service is very important. Understand the manufacturer's after-sales service policy, such as whether free installation, repair, replacement and other services are provided, as well as details such as after-sales service response time and service scope. For example, some brands promise a warranty period of no less than 3 years and can handle faults on site within 48 hours.

Compare brand market share and popularity: Generally speaking, brands with a larger market share and higher popularity have more guaranteed product quality and service. Such brands usually invest more in R&D, production and sales, and their products have been widely tested in the market. For example, Philips, Opple Lighting, NVC Lighting, etc. have high popularity and market recognition in the field of warehouse lighting.

Examine the brand's R&D and innovation capabilities: Brands with strong R&D and innovation capabilities can continuously launch products with better performance and better meet market demand. You can observe the frequency of the brand's new product launches and whether it has won relevant design awards or technology patents, etc. These can reflect the brand's innovative strength.

How to judge the quality of warehouse lighting fixtures?

To judge the quality of warehouse lighting fixtures, it is necessary to comprehensively evaluate from multiple dimensions such as core performance, material technology, safety certification, and actual testing, especially in combination with special usage scenarios of warehouses (such as high space, dusty, and long-term stable operation). The following is a specific judgment method:

Core performance: directly affects lighting effect and lifespan

1. Light source performance (LED is the mainstream, focus on these 3 points)

Luminous efficiency (lm/W): that is, the luminous flux generated per watt of power. The higher the value, the more energy-saving it is.

Qualified standard for warehouse lamps: ≥80 lm/W; high-quality standard: ≥100 lm/W (such as luminous flux of 100W lamps ≥10000 lm).

Judgment method: Check the product parameter table, or use professional equipment (such as illuminance meter) to test - at the same power, at the same distance to illuminate the same area, the higher the illuminance (lux), the better the light effect.

Light decay speed: The speed at which the brightness of the light source decays with the use time directly determines the lifespan.

Qualified standard: 1000 hours light decay ≤5%, 5000 hours light decay ≤10%; high quality standard: 10000 hours light decay ≤15% (close to the core requirement of "50,000 hours of life").

Judgment method: give priority to brands marked with "light decay curve" (such as well-known brands will provide third-party test reports), and avoid low-priced products without data (may be significantly darkened in 1-2 years).

Color rendering index (Ra): measures the ability of light sources to restore the true color of objects (although warehouses are not precision scenes, too low will affect the identification of goods).

Qualified standard: Ra ≥ 60 (can distinguish basic colors); high quality standard: Ra ≥ 70 (goods color identification is clearer, especially suitable for e-commerce and food warehouses).

Judgment method: use the same colored goods (such as red cartons) to compare under different lamps, lamps with poor color rendering will make the color gray and yellow.

2. Driver power performance (the "heart" of LED, determines stability)

Driver type: must be constant current drive (output current is stable), not constant voltage drive.

Constant current drive can avoid voltage fluctuations (which are easily caused by the start and stop of large equipment in warehouses) on LED chips and reduce the risk of damage; constant voltage drive may burn the chip when the voltage fluctuates.

Judgment method: check the product description, or disassemble the shell (requires professionals) to observe the driver label, and the ones marked "constant current output" and "DCXXV" are more reliable.

Conversion efficiency: The efficiency of the driver in converting AC power to DC power. The higher the efficiency, the more energy-saving and the less heat generation.

Qualified standard: ≥85%; high-quality standard: ≥90% (low-efficiency drivers are prone to burn out due to overheating).

Judgment method: By comparison - for lamps with the same power, the shell (especially the driver part) temperature is higher when the driver efficiency is low.

Protection function: high-quality drivers will have built-in overvoltage, overcurrent, short-circuit protection, and even "lightning protection" design (suitable for outdoor warehouses or areas prone to thunderstorms).

Judgment method: Check whether the product parameters are marked with "protection function", or ask the manufacturer whether it has undergone relevant tests (such as voltage fluctuation test).

Material and process: affecting durability and safety

1. Shell and heat dissipation structure (key to high temperature/dust environment in warehouse)

Material: Die-cast aluminum (good heat dissipation and high strength) is preferred, followed by profile aluminum; avoid plastic shell (poor heat dissipation, easy to age and deform under long-term high temperature).

Judgment method: weigh the weight of the lamp (die-cast aluminum is heavier at the same power), or test with a magnet (aluminum does not attract magnetism, and inferior products may be painted with iron shells).

Heat dissipation design: The shell should have large-area heat dissipation fins (similar to computer graphics card heat sinks), and the fin spacing should be reasonable (convenient for air circulation); the internal chip and the shell should be tightly connected through "thermal conductive silicone" or "copper pillars" (to ensure rapid heat conduction).

Judgment method: Observe whether the shell has regular heat dissipation fins, touch the shell at the corresponding position of the chip (after running for 1 hour), if the temperature is uniform and not hot (≤60℃), it means that the heat dissipation is good.

Protection level (IP): Select according to the warehouse environment, which directly affects the dust and moisture resistance.

Dry, dust-free warehouses (such as electronic warehouses): IP54 and above (splash water + dustproof);
Dusty (building materials warehouses) or humid (agricultural product warehouses): IP65 and above (completely dustproof + low-pressure water spray proof);

Explosion-proof warehouses (chemicals): require additional explosion-proof certification (such as Ex), and the shell has no exposed gaps.
Judgment method: Check whether the lamp label is marked with IP level, or use a spray bottle to spray water mist (IP65 should not have water ingress), cover the dust and wipe it (IP65 dust should not enter the interior).

2. Light source and accessories details

LED chips: Prioritize imported chips (such as Cree, Osram, Samsung) or domestic first-line brands (such as Sanan Optoelectronics), which have slow light decay and strong stability; inferior chips (packaged by small factories) may have a light decay of more than 50% after 1 year.

Judgment method: consult the manufacturer about the chip brand, or check the laser engraving on the chip (well-known brands have logos).

Lens/lampshade: Warehouse high-space lamps (such as industrial and mining lamps) need to be equipped with high-transmittance lenses (transmittance ≥ 90%), and the material should be tempered glass or high-purity PC (impact-resistant and not easy to yellow); avoid ordinary plastic lampshades (easy to accumulate dust, yellowing in 1-2 years and poor light transmittance).

Judgment method: observe whether the lampshade is transparent and free of impurities, and scratch it lightly with your fingernail (PC or glass is not easy to leave marks, and inferior plastic is easy to scratch).

Wiring terminals: Internal wiring should use pure copper terminals (good conductivity, not easy to oxidize), and have an "anti-loosening" design (such as screw fixing + spring clamping); avoid aluminum wires or inferior terminals (easy to heat up due to poor contact, causing short circuits).

Judgment method: disassemble the junction box (after power off), observe the terminal color (pure copper is purple-red, aluminum wire is silver-white), and pull the wiring hard (high-quality terminals are not easy to fall off).

Safety certification: Avoid potential risks

Mandatory certification: Lamps sold domestically must have CCC certification (China Compulsory Product Certification), and the label will have a "CCC" mark and certificate number (authenticity can be checked on the official website of the National Certification and Accreditation Administration).

Note: Lamps without CCC certification may have circuit design defects, which may cause electric shock or fire risks.

Additional certification: Choose according to needs ——

Export or high-demand warehouse: CE (EU), UL (USA) certification;

Energy-saving project: China Energy Efficiency Label (Level 1 is the most energy-saving);

Explosion-proof scene: Ex explosion-proof certification (need to correspond to the warehouse hazard level, such as Ex dⅡCT4).

 Actual test and word of mouth: verify the real performance

Small batch trial: first purchase 1-2 lamps and install them in typical locations of the warehouse (such as high shelf areas and corners), run for 1-3 months and observe:

Light decay: use a illuminance meter to compare the initial and 3-month illumination (the decay of high-quality lamps should be ≤5%);

Stability: whether there is flickering or flickering (possible driver or wiring problems);

Environmental resistance: whether dust accumulation in dusty areas affects brightness, and whether there is rust or water ingress in humid areas.

Reference to user word of mouth: consult the brands used by warehouses in the same industry (such as logistics parks and factory warehouses), and give priority to products that "run for more than 3 years without large-scale damage"; avoid low-priced products with "frequent burnout" and "fast light decay" in online reviews.

Manufacturer after-sales commitment: high-quality brands will provide a warranty of 3 years or more (core components such as drivers and chips are separately warranted), and clearly state that "non-human damage can be replaced free of charge"; short warranty period (within 1 year) or vague commitments may indicate lack of confidence in quality.

How does the material process of warehouse lighting fixtures affect the quality of the fixtures?

The material and craftsmanship of warehouse lighting fixtures are the core factors that determine their durability, stability, and safety, and directly affect the service life and lighting effect of the lamps in the special environment of the warehouse (high space, dusty, long-term operation, possible vibration or humidity). The impact of the material and craftsmanship of different components on quality is as follows:

Shell material and craftsmanship: determine durability and heat dissipation capacity

Warehouse lamps need to be exposed to the air for a long time (some environments have dust, water vapor and even slight corrosion), and their own operation will generate heat. The material and craftsmanship of the shell are directly related to "whether it is durable" and "whether it can work stably for a long time".

1. Material selection: affects corrosion resistance, strength and heat dissipation

Die-cast aluminum (preferred)

Advantages:

Excellent heat dissipation (aluminum's thermal conductivity is more than 3 times that of iron), can quickly transfer the heat generated by the light source and driver to the air, and avoid high temperature causing chip aging or driver burning;

High strength (compact structure after die-casting), impact resistance (such as warehouse forklift operation may splash debris), strong deformation resistance;

The surface can be treated by "anodization" or "electrostatic spraying" to form a corrosion-resistant coating (especially suitable for warehouses with high dust and slight corrosion such as building materials and chemicals).

Process requirements: "one-time die-casting" (no welding seams) is required to avoid inferior processes (such as splicing or thin aluminum sheet stamping) - the splicing is prone to dust accumulation and water ingress, and the thin aluminum sheet has insufficient heat dissipation area and will deform after long-term use.

Aluminum profile (second choice)

Advantages: The cost is lower than die-cast aluminum. The shell is made by cutting and splicing, which is suitable for small and medium-sized lamps (such as below 100W);

Limitations: Heat dissipation depends on the surface area of the profile itself (sufficient heat dissipation fins need to be designed). If the joints are not sealed well, dust will easily enter and affect the internal components.

Poor quality materials (need to be avoided)

Plastic shell (such as ABS): extremely poor heat dissipation, long-term operation (especially high-power lamps above 100W) will age, deform, or even melt due to high temperature and cause short circuits;

Iron sheet/iron shell: easy to rust (especially in humid warehouses), poor thermal conductivity, heavy weight but low strength (easy to be deformed by collision).

2. Process details: affecting sealing and heat dissipation efficiency

Surface treatment process:

The die-cast aluminum shell needs to be "sandblasted + anodized" (forming an oxide film, anti-corrosion, easy to clean) or "electrostatic powder spraying" (uniform color, strong adhesion, not easy to fall off);

Poor quality process: direct spray painting (the paint film is thin and easy to fall off, and the exposed aluminum will oxidize and turn black when it encounters water vapor, affecting heat dissipation).

Sealing process: In view of the need for dust and moisture resistance (the core guarantee of IP level), silicone rubber sealing rings (high and low temperature resistance, not easy to age) are required at the joints of the lamps and lanterns, and "press-fit sealing" (rather than simple pasting) - inferior products may use ordinary rubber rings (hardening and failure in 1-2 years) or no sealing rings, causing dust and water vapor to enter the internal components and damage them.

Light source and chip packaging process: determine the light effect and light decay

The light source of warehouse lamps (mainly LED) is the core of lighting, and its chip quality and packaging process directly affect the brightness, life and stability.

1. LED chip material

High-quality chip: using sapphire substrate + gallium nitride (GaN) epitaxial layer (such as Cree, Osram, Sanan Optoelectronics chips), high electron mobility, stable luminous efficiency, 10,000 hours of light decay can be controlled within 15%;

Poor-quality chip: made of silicon substrate or recycled material, with many impurities, easy to heat when current passes through, 3000-5000 hours of light decay may exceed 30% (the lamp becomes obviously darker), and even "dead light" (partially not bright) may appear.

2. Packaging process

Packaging material:

High-quality products: Use high-purity silica gel (transmittance ≥ 95%, yellowing resistance) to encapsulate the chip, and the lens uses tempered glass or imported PC (polycarbonate) (impact-resistant, long-term use of light transmittance decreases ≤ 5%);

Poor-quality products: Use ordinary epoxy resin (easy to yellow, 1 year light transmittance decreases by more than 30%) or recycled PC (easy to crack, dust accumulation), resulting in rapid brightness decay.

Heat dissipation connection process: The chip needs to be fixed on the heat dissipation bracket through heat-conducting silver glue or eutectic welding (directly connected to the metal substrate) - high-quality technology can allow the heat of the chip to be transferred to the shell "zero barrier"; inferior products are pasted with ordinary glue, which has poor thermal conductivity and the chip is easily burned due to overheating.

Drive power material and circuit technology: determine stability and safety

The drive power is the "heart" of the LED lamp (converting AC power into stable DC power), and its material and circuit design directly affect whether the lamp is "resistant to voltage fluctuations" and "anti-short circuit".

1. Core component material

Capacitor: solid capacitor for high-quality drive (high temperature resistance ≥105℃, life ≥50,000 hours), not liquid electrolytic capacitor (temperature resistance ≤85℃, easy to bulge and fail at high temperature, life is only 10,000-20,000 hours);
Transformer: wound with high-purity copper wire (high conductivity, less heat), silicon steel sheet for iron core (reduce magnetic loss); inferior drive with aluminum wire (high resistance, easy to heat) or inferior iron core, low conversion efficiency (≤70%), and easy to burn due to overload.

2. Circuit technology

PCB board: flame-retardant PCB board (FR-4 grade) for high-quality drive, regular circuit layout (avoid cross interference), full solder joints (no false solder joints, leaking solder joints); inferior PCB board is non-flame-retardant material (easy to burn at high temperature), with many solder joints and burrs, and long-term vibration (such as warehouse equipment operation) may fall off and cause short circuit.

Protection circuit design: high-quality drivers will integrate overvoltage, overcurrent, and short-circuit protection chips (such as "protection function" marked on the IC model), and can automatically cut off the power for protection when the voltage fluctuates (such as starting and stopping large equipment in the warehouse); low-quality drivers have no protection design, and will burn directly when the voltage is abnormal, and even cause the lamp to catch fire.

Accessory material: details affect overall reliability

Although the small accessories of warehouse lamps (such as wiring terminals, brackets, and screws) are inconspicuous, poor material craftsmanship will lead to "chain failures".

Wiring terminals:

High-quality products: use pure copper terminals (nickel-plated surface to prevent oxidation), with shrapnel-type clamping structure (not easy to loosen after wiring);

Low-quality products: use aluminum terminals (easy to oxidize, resulting in poor contact, heat and sparks) or plastic terminals (deformed at high temperatures, falling off and causing power outages).

Mounting bracket:

Lights in high-space warehouses (e.g., more than 10 meters) need to be suspended and mounted, and the brackets need to be made of galvanized steel or aluminum alloy (bearing ≥5 times the weight of the lamp, rust-resistant);

Poor-quality brackets use thin iron sheets (easy to bend and break) or no anti-rust treatment (rusts in a humid environment in 1 year, and there is a risk of falling).

Screws and other connectors: Stainless steel screws (rust-resistant) are required, not ordinary iron screws (easy to rust and get stuck, and cannot be disassembled for later maintenance).

Conclusion: The material and craftsmanship of warehouse lamps determine whether they can operate stably and for a long time in harsh environments. High-quality materials (die-cast aluminum, imported chips, solid-state capacitors) + fine craftsmanship (sealing, welding, heat dissipation design) can make the lamp life reach 5-8 years; while lamps with inferior materials + rough craftsmanship often have serious light decay, burnout, and fall off in 1-2 years, which increases replacement and maintenance costs. When choosing, you need to focus on the shell material, heat dissipation design, driver component markings and sealing details to avoid "looking at the price instead of the material".

What are the advantages and disadvantages of aluminum alloy and stainless steel shells?

Aluminum alloy and stainless steel are two common materials for warehouse lighting housings. The performance differences between the two are mainly reflected in heat dissipation, corrosion resistance, strength, weight, cost, etc. The applicable scenarios also vary depending on the warehouse environment (such as dust, humidity, corrosion, and whether it needs to bear weight). The following is a specific comparison:

1. Aluminum alloy housing: "heat dissipation" and "lightweight" are the core advantages

Aluminum alloy (especially die-cast aluminum and profile aluminum) is the mainstream choice for warehouse lamps. Its performance adapts to the core needs of warehouses for "long-term high-power operation and heat dissipation", while taking into account basic durability.

Advantages:

Strong heat dissipation capacity

The thermal conductivity of aluminum (about 237 W/(m・K)) is more than 10 times that of stainless steel (about 15-20 W/(m・K) for stainless steel), which can quickly conduct the heat generated by the light source (LED chip) and the driver power supply to the surface of the housing, and then dissipate it through air convection. This is crucial for warehouse lamps - warehouse lamps usually have high power (50W-200W) and run 10-12 hours a day. High temperature will accelerate chip aging and driver component failure, while aluminum alloy shells can significantly delay this process and extend the life of lamps (high-quality aluminum alloy lamps can last up to 5-8 years).

Lightweight, safer installation

The density of aluminum alloy (about 2.7 g/cm³) is only 1/3 of that of stainless steel (about 7.9 g/cm³ for stainless steel). Warehouse lamps are mostly suspended in high spaces (such as 8-15 meters in height). Lightweight shells can reduce the load-bearing requirements of the suspension bracket and reduce the risk of "bracket deformation and lamp falling after long-term suspension"; at the same time, it is more labor-saving to carry and install, reducing construction costs.

Flexible molding process, suitable for complex structures

Aluminum alloy can be processed through processes such as "die casting" (one-time molding of complex shells, no joints), "profile cutting" (making heat dissipation fins), etc., and can design a structure that meets the heat dissipation requirements (such as adding fins and grooves on the shell surface to expand the heat dissipation area). For example, the shell of high-power warehouse lights often adopts the "die-cast aluminum + multi-fin" design, and the heat dissipation efficiency is more than 40% higher than that of flat structures.

Moderate cost and high cost performance

The cost of aluminum alloy raw materials is lower than that of stainless steel (especially 304 stainless steel), and the processing difficulty is low (die casting and cutting processes are mature), which is suitable for mass production. The overall cost of lamps is easier to control, taking into account performance and economy.

Disadvantages:

Weak corrosion resistance (needs to rely on surface treatment)

Pure aluminum alloy is easily corroded by acid, alkali, and salt spray (such as chemical warehouses and coastal humid warehouses containing salt in water vapor). If the surface treatment process is poor (such as simple spray painting), oxidation and blackening and coating shedding will occur in 1-2 years. It is necessary to improve the corrosion resistance through processes such as "anodizing", "electrostatic spraying" and "electrophoresis" (after treatment, it can meet the general dust and humid environment, but it is still necessary to be cautious in the strong corrosion environment).

The strength is lower than that of stainless steel (limited impact resistance)

The hardness of aluminum alloy (Brinell hardness is about 60-100) is lower than that of stainless steel (304 stainless steel is about 160-200). If the shell thickness is insufficient (inferior products are made thin to reduce costs), it may be dented by hard objects splashed by warehouse forklifts, or even deformed and cause damage to internal components.

2. Stainless steel shell: with "extreme corrosion resistance" and "high strength" as the core advantages

The core advantage of stainless steel (commonly used 304, 316 models) is "rust resistance", which is suitable for scenes with strong corrosion, high humidity, and high dust (containing acid and alkali components) in the warehouse environment, but there are obvious shortcomings in heat dissipation and lightweight.

Advantages:

Extremely corrosion-resistant, almost "maintenance-free"

304 stainless steel contains 18% chromium and 8% nickel, and forms a passivation film (chromium oxide) on the surface, which can resist corrosion from water, steam, weak acids and alkalis (such as water vapor in food warehouses and dust in ordinary chemical warehouses). The shell will not rust after long-term use (5-10 years);

316 stainless steel (containing molybdenum) can withstand seawater, strong acids and alkalis (such as corrosive gases in fertilizer and pesticide warehouses), and is a "must-have choice" for highly corrosive environments.

No need to rely on surface coating (the coating can still self-repair the passivation film after damage), suitable for warehouses that are difficult to maintain regularly (such as high shelves and deep alley warehouses).

High strength, strong impact and deformation resistance

The tensile strength of stainless steel (304 about 520MPa) is 1.5-2 times that of aluminum alloy (about 200-300MPa). The shell can be made thin but still maintain high strength (for example, the impact resistance of 1mm thick stainless steel shell is better than that of 2mm thick aluminum alloy). In warehouses with heavy equipment operations (such as machining warehouses, where metal debris may fall), stainless steel shells are more difficult to be damaged.

High temperature and aging resistance, extremely long life

Stainless steel has stable performance (no deformation, cracking) at high temperature (less than 200℃), and does not age (compared with plastic shells). With high-quality light sources and drivers, the overall life can be up to 8-10 years, which is suitable for warehouses with extremely high requirements for "low replacement frequency" (such as cold chain warehouses, where lamp replacement requires shutdown and high cost).

Disadvantages:

Poor heat dissipation, restricting the application of high-power lamps

The thermal conductivity of stainless steel is low (only 1/10 of that of aluminum alloy), and it cannot quickly export the heat of the light source and driver. If used for high-power lamps above 100W, insufficient heat dissipation may cause:
Accelerated light decay of LED chips (light decay may reach 30% in 10,000 hours, while aluminum alloy shell is only 15%);

Overheating and burning of driver power capacitors and transformers (especially in high-temperature environments in summer). Therefore, stainless steel shells are more suitable for low-power lamps below 50W, or additional heat dissipation modules (such as built-in aluminum heat sinks) are required, but this will increase cost and weight.

Heavy weight, high installation and load-bearing requirements

The density of stainless steel is 3 times that of aluminum alloy, and the weight is much larger at the same volume. For example, the stainless steel shell (including bracket) of a 100W lamp is about 3-4kg, while the aluminum alloy shell is only 1-1.5kg. When hanging in high space, a stronger bracket (such as a thickened galvanized steel bracket) and a stronger ceiling structure are required, which increases the installation cost; and long-term hanging may cause the bracket to deform due to its own weight.

Difficult processing and high cost

Stainless steel has high hardness, and the cutting, welding and polishing processes are complicated (for example, grinding and polishing are required after welding to prevent rusting of welding points). The efficiency of mass production is low, and the raw materials (especially 316 stainless steel) and processing costs are 30%-50% higher than aluminum alloys, resulting in high prices for lamps, and the cost-effectiveness is only prominent in special environments.

3. Comparison of applicable scenarios: Aluminum alloy or stainless steel?

 

No matter which material you choose, you need to pay attention to the process details (such as the die-casting integrity of aluminum alloys and the welding and grinding quality of stainless steel) to avoid quality problems caused by "materials meet the standards but the workmanship is rough" (such as dust leakage at aluminum alloy joints and rust at stainless steel welds).

Does the shape of the shell of warehouse lighting fixtures affect heat dissipation?

The shell shape of warehouse lighting fixtures has a significant impact on heat dissipation. The core logic of heat dissipation is "to quickly transfer the heat generated by the light source (LED chip) and the driver power supply to the shell, and dissipate it through the contact between the shell and the air", and the shell shape directly determines the heat conduction efficiency and heat dissipation area, which in turn affects the heat dissipation effect of the lamp (ultimately affecting the life and light decay speed).

The core principle of the shell shape affecting heat dissipation

When the lamp is running, the LED chip (about 70%-80% of the electrical energy is converted into heat) and the driver power supply will continue to generate heat. If the heat cannot be dissipated in time, the internal temperature will rise (after exceeding 60℃, the LED light decay will accelerate; above 80℃, the driver component is prone to aging and failure).

The role of the shell is "heat conduction medium":

Conduction stage: The shell needs to be designed in shape (such as a structure that fits the light source) to allow heat to be quickly transferred from the internal components to the shell;

Dissipation stage: The shell needs to expand the contact area with the air through the shape, or guide the air flow to accelerate heat dissipation.

Comparison of heat dissipation effects of different shell shapes (with pros and cons analysis)

1. Polyhedron shape with "heat dissipation fins" (optimal heat dissipation design)

This is the mainstream design of high-power warehouse lamps (above 100W), commonly seen in aluminum alloy shells (the thermal conductivity of aluminum is suitable for fin conduction).

Shape characteristics: The main body of the shell is flat or curved, and long strips of "fins" are evenly distributed on the surface (similar to computer CPU radiators), with a fin spacing of 5-10mm and a height of 5-20mm; some designs will add grooves at the root of the fins, or reserve ventilation holes at the bottom of the shell.

Heat dissipation principle:

Expand the heat dissipation area: The fins increase the surface area of the shell by 30%-60% compared with the flat shape (for example, for a 100W lamp, the flat shell area is about 0.05㎡, and it can reach 0.08㎡ with fins), and it is more fully in contact with the air;

Guide air convection: The gaps between the fins form an "air duct", and the natural airflow in the warehouse (or fan-assisted) can pass through the gaps to take away the heat on the surface of the fins.

Advantages: The heat dissipation efficiency is more than 40% higher than other shapes, and can support the long-term operation of 100-200W high-power lamps (when the ambient temperature is 35℃, the surface temperature of the shell can be controlled within 50℃, which is much lower than the tolerance temperature of the LED chip).

Note: The fins need to be integrally formed with the shell (die-casting process). If they are spliced later (inferior products are glued to reduce costs), poor contact will cause heat conduction interruption and heat dissipation failure.

2. Flat/arc-shaped smooth shell (basic heat dissipation, suitable for low power)

Common in small and medium-power lamps (below 50W) or scenes with simple appearance requirements.

Shape features: The shell is a flat rectangular or circular flat plate with no raised structure on the surface. It conducts heat only through its own material (such as aluminum alloy) and relies on natural heat dissipation on the surface.

Heat dissipation principle: After the heat is conducted from the inside to the surface of the flat plate, it is dissipated through "thermal radiation" and "surface air natural convection" (no active air duct design).

Advantages: simple structure, low cost (easy processing), suitable for low-power lamps (less heat generation, no need to enhance heat dissipation); smooth surface and easy to clean, suitable for warehouses with more dust (reduce the problem of dust accumulation blocking the heat dissipation holes).

Disadvantages: The heat dissipation area is limited. If used for high-power lamps (such as above 100W), the surface temperature of the shell will rise rapidly (may exceed 60℃), resulting in accelerated aging of internal components (lifespan shortened by more than 30%).

3. Sealed closed shape (worst heat dissipation, only special environments)

Some warehouses need to seal lamps due to "high humidity and strong dust" (such as food cold storage and flour warehouse) (to prevent water vapor/dust from entering the interior), and the shell is often designed as a fully enclosed structure (no ventilation holes, no gaps).

Shape characteristics: The shell is a complete enclosed cavity (such as cylindrical, square), with only a light-transmitting panel (glass or acrylic) at the bottom, and almost no circulation with the outside air.

Heat dissipation principle: Heat is completely transferred to the outer surface by the shell material, and then dissipated through the surface (without air convection assistance), and the heat dissipation efficiency is extremely low.

Advantages: High protection level (IP65 and above), can isolate water vapor and dust, suitable for special environments.

Disadvantages: Poor heat dissipation capacity, even for 50W lamps, the internal temperature may exceed 70℃ after continuous operation for 8 hours, and it needs to be matched with "built-in aluminum heat sink" or "low heat source" (such as low-power LED), and the life is usually 20%-30% shorter than that of non-sealed lamps.

Improved design: High-quality sealed lamps will add "micro-convex patterns" on the surface of the shell (instead of fins to avoid dust accumulation), or use "one-piece molding of the shell and internal heat sink" (reducing heat conduction resistance) to slightly improve heat dissipation.

4. Hollow shape with "bottom vents" (taking into account heat dissipation and protection)

For "medium dust, non-corrosive" warehouses (such as e-commerce warehouses), some lamps are designed as hollow structures with "top sealing and bottom/side vents".

Shape features: The main body of the shell is a frame structure, with grid-shaped vents on the side or bottom (aperture 3-5mm to prevent large particles of dust from entering), and the internal light source module is directly in contact with the outside air.
Heat dissipation principle: Air flows naturally through the vents, directly taking away the heat of the light source and driver (without relying entirely on shell conduction), and the heat dissipation efficiency is close to the fin design.

Advantages: Good heat dissipation (30% higher than flat shells), and the vents are small in diameter, which can block most dust (protection level IP54, suitable for general dust environments).

Disadvantages: The vents may be blocked by long-term accumulation of fine dust (such as flour warehouses), and need to be cleaned regularly (otherwise the heat dissipation efficiency will drop by more than 50%); not suitable for high humidity environments (water vapor can easily enter the interior through the vents).

Summary: How to judge the heat dissipation capacity by the shape of the shell?

Give priority to "integrated fin structure": high-power lamps (above 100W), ordinary dry warehouses - the more fins and the reasonable spacing (5-10mm), the better the heat dissipation (pay attention to check whether the fins are seamlessly connected to the shell).

Flat shells are only used for low power: lamps below 50W, dusty scenes that need to be easy to clean - avoid using them for high power, otherwise they are prone to overheating.

Choose sealed shells carefully: only used in high humidity/strong dust environments, and must be paired with low-power light sources (≤50W), and confirm whether the shell has auxiliary heat dissipation designs such as micro-textures.

Hollow ventilation structure for protection: suitable for medium dust and dry warehouses, the ventilation holes need to be cleaned regularly (the manufacturer can be asked to design a removable dust net for easy maintenance).

In short, the core of the shell shape is "to maximize the heat dissipation area and air circulation efficiency while meeting the warehouse environment protection requirements (dustproof, waterproof, impact-resistant)" - the more the heat dissipation design fits this logic, the better the quality of the lamp can ensure long-term stable operation.

FAQ for warehouse lighting fixtures

The following are common FAQs (Frequently Asked Questions and Answers) in the purchase, use and maintenance of warehouse lighting fixtures, covering core scenarios such as selection, performance, installation, and maintenance, to help quickly solve practical problems:

Selection category: How to choose lamps suitable for warehouses?

1. Should warehouse lamps be LED or traditional metal halide lamps/fluorescent lamps?

LED must be selected. Compared with traditional lamps:

Energy consumption: LED saves 60%-70% energy compared to metal halide lamps (100W LED brightness ≈ 250W metal halide lamps), warehouse lighting time is usually 10-12 hours/day, and annual electricity bills can be saved by more than half;

Lifespan: LED lifespan is 50,000-80,000 hours (metal halide lamps are only 8,000-15,000 hours), reducing the cost of frequent replacement (especially high-shelf warehouses require climbing equipment to change lights, and labor costs are high);

Stability: LED starts without delay and is vibration-resistant (metal halide lamps take 5-10 minutes to start, and the filament is easily broken, which is not suitable for warehouses with frequent forklift operations).

The only thing to note: LEDs are sensitive to temperature, so you need to choose models with good heat dissipation (refer to the previous "shell shape" related content).

2. What power lamps should be selected for warehouses with different floor heights?

The floor height determines the installation height of the lamp. The higher the height, the greater the power and farther the illumination distance (to avoid insufficient brightness on the ground):