Conveyor Belt LED Lighting Solutions

Advanced Optical Design Inside the Extremely Rugged MR Series Case

Having spent the last two decades on some of the toughest industrial sites in Northern Canada, our team has frequently been asked to address challenges related to conventional HID as well as some newer generation LED lights when used as Conveyor Belt Lights.

Frequent lamp and ballast replacements, poor lighting quality, high power consumption, susceptible to impact and vibration damage, a poor color rendering index, as well as excess power consumption, were some of the main concerns with older HID lights. Upgrading to certain LED products could address a few of the issues, but many systems are not designed to withstand the harsh environment, do not deliver optimize lighting distribution, and can rely on the substantial tilting of the light engines creating a challenge with excessive glare for the operators and non-compliance with basic Dark Sky guidelines were lighting beyond the horizon is prohibited.

Standard: Illuminating conveyor belts and adjacent walkways with conventional HID as well as most standard LED luminaires is typically achieved by installing a light fixture every 6 meters.
Nemalux: The use of advanced optics can allow for 12 meters spacing and deliver a 50% reduction in overall quantities, generating substantial cost and energy savings.

Using Nemalux’s solid-state MR Series as the base platform for the application, we can address all outlined challenges with the existing solutions, while providing a Made in Canada product to our industrial customers in the Americas.

The high-pressure die-cast aluminum housing with marine grade alloy as well as polycarbonate lenses creates an enclosure that can withstand impact and constant vibration. Mounting brackets designed to carry substantially heavier LED lights prevent stress fractures and breaks. Stainless steel fasteners are secured in place with thread locker to prevent loosening while allowing access for future upgrades.

LEDs and power supplies are rated for over 60,000 hours of operation prior to experiencing a 20% reduction in light output and can withstand ambient temperatures of – 40°C to + 55°C.

Optional 3,000K LEDs with a high color rendering index as well as full cut-off perimeter rings offer a fully Dark Skye compliant system when used in combination with our non-adjustable brackets.

MR pole mounts allow the installation of our lights with a 0° tilt while internal Type 1 secondary optics enable pole spacing of up to 12m when targeting 40-50lux on walkways. In addition, the textured/frosted protective lens of the MR substantially improves visual comfort for operators while eliminating the need to tilt the light engines.

In summary, reducing power consumption, reducing the overall number of lights and maintenance costs does not need to come at the cost of visual comfort and operator satisfaction. A cost-effective solution from Nemalux can address most challenges connected to older HID technology and less refined LED options on the market.

How can we help you?

We’d love to help with your industrial LED lighting solutions. Please feel free to contact our staff at any time.

Nemalux takes pride in designing and manufacturing industry leading industrial and hazardous location outdoor LED lighting solutions.

Nemalux Industrial | Staff
Sam Pogosian
CEO, Nemalux Inc.

Problem to Solve

  • Frequent Fixture Maintenance
  • Poor Light Quality & Distribution
  • High Costs

How we solve the problem(s) uniquely:

  1. Nemalux-Specific Fixture Design
    • High-pressure die-cast aluminum housing with marine grade alloy, designed to safeguard power supply and diodes from overheating.
    • Triple-layer, best-available, powder coat finish.
    • Polycarbonate lenses seal the enclosure to withstand direct impact, extreme vibration, and corrosive materials.
    • Nemalux Equalization Valve prevents internal condensation accumulation while maintaining an IP66/67 seal and hazardous location ratings.
  1. Higher Performing Optics
    • 10+ Optic options
    • Lumens delivered in the distribution pattern
  1. Mounting Options
    • Nemalux mounting brackets are over-designed to prevent stress fractures and subsequent failures.
    • Stainless steel fasteners are secured in place with thread locker to prevent loosening while allowing access for future upgrades.
    • Adapters are available reliably seal fixtures to existing mounts that are not being replaced.
    • For new installations, fixtures can be delivered pre-assembled on adjustable or fixed stanchions to reduce installation costs.
  1. CCT Options
    • Optional 3,000K LEDs with a high color rendering index ensure excellent vision in all weather conditions.
  1. Dark Sky Compliance

Common Use Case

Illumination of material transfer conveyor belts and adjacent walkways.

Illumination Recommendations for Safety and Operational Considerations (IESNA Handbook):

 

Conveyor Transfer Points

Average Horizontal Illuminance Recommendation: 50 Lux / 5 FC

Average Vertical Illuminance Recommendation: 50 Lux / 5 FC

Uniformity Ratio Recommendation (Max : Min) : < 5:1

 

Conveyor

Average Horizontal Illuminance Recommendation: 20 Lux / 2 FC

Average Vertical Illuminance Recommendation: 20 Lux / 2 FC

Uniformity Ratio Recommendation (Max : Min) : < 10:1

 

Active Walkway

Average Horizontal Illuminance Recommendation: 50 Lux / 5 FC

Average Vertical Illuminance Recommendation: 15 Lux / 1.5 FC

Uniformity Ratio Recommendation (Max : Min) : < 5:1

 

Inactive Walkway

Average Horizontal Illuminance Recommendation: 10 Lux / 1 FC

Average Vertical Illuminance Recommendation: 2 Lux / 0,2 FC

Uniformity Ratio Recommendation (Max : Min) : < 10:1

Outcome of the Solution (Why Choose Nemalux?)

  • Improved Site Safety
  • Better Visibility in all weather conditions
  • Reduced Maintenance with Superior Product Reliability
  • Dark Sky Compliance and reduced light trespass
  • Lower Cost; Faster Delivery; Greater Support

Products of Interest for Conveyor Belt Lighting Solutions

MR

The MR is a unique multi-functional, feature rich light fixture based on our rigorous design, prototyping, testing and refinement process. Using industry leading manufacturing practices, our engineers and industrial designers were able to produce a fixture that not only exceeds the expectations of an HID replacement, but establishes a new benchmark in versatility for industrial LED lighting.

XR

(If elevated light levels are required for increased visibility)

Nemalux’s XR is built on the same design philosophy as our previous multi-purpose LED lights that can address a wide range of challenging applications in the light and heavy industrial workplaces. XRs are factory programmed to offer light outputs ranging from 8,000 to 20,000 lumen. Auto-ranging power supplies allow operation on 120-277 VAC or 347-480 VAC. Optional 0-10V dimming provides further opportunities for fine-tuned illumination results based on facility and operator preference.

Click above to see our wide range of industrial LED lighting solutions and case studies.

To discuss your requirements with one of our LED Lighting experts, call or email us today.

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Your Trusted Industrial Lighting and Hazardous Location Lighting LED Experts

Nemalux Industrial