_thumb.jpg)
Automotive Factory Uses HB01 LED High Bay Light
Case Study: Automotive Factory Cuts Energy Use by 48% with Ceramiclite HB01
Customer Background
A global automotive parts manufacturer operating a 24/7 production facility with high ceilings, chemical vapors, and constant mechanical operations.
The plant spans 12,000 m², operating 24/7 across three shifts. High ceilings (~ 10 m) and heavy machinery lines producing metal components expose lighting to chemical vapors (sulfur, ammonia), dust, and periodic coolant mist. Previous 1.2 kW metal-halide fixtures suffered frequent ballast failures and flicker under vibration. Poor color rendering affected visual inspection quality, and irregular illumination led to QC errors and rework.
.jpg)
The Challenges
The factory’s previous metal halide fixtures created persistent issues:
-
High energy consumption
Traditional lighting systems consumed excessive power, driving up monthly operational costs and putting pressure on the facility’s energy budget.
-
.png)
Severe corrosion from airborne chemicals
Airborne sulfur, ammonia, and chemical vapors caused rapid corrosion of conventional fixtures, leading to rust, damage, and safety risks.
-
.jpg)
Frequent lamp failures
Old lamps failed repeatedly under harsh conditions, resulting in constant replacements and unreliable lighting across the workspace.
-
Flicker illumination affecting worker productivity
Flickering lights strained worker visibility, increased fatigue, and reduced on-site productivity.
-
Uneven illumination affecting factory manufacturing
Patchy, uneven illumination left workers struggling to see clearly, slowing productivity and increasing the risk of operational errors.
-
.png)
Expensive shutdowns for maintenance
Frequent lighting failures forced the facility into costly maintenance shutdowns, disrupting production and increasing labor expenses.
Ceramiclite LED Lighting Solution
Ceramiclite upgraded the facility with HB01 Industrial LED High Bay Lights, engineered for harsh industrial conditions.
Key features of Ceramiclite Solution
-
Ceramic LED modules with exceptional sulfuration resistance & corrosion resistance.
-
IP67/IP69K anti-dust, anti-moisture, and anti-chemical housing
-
Custom beam angles for optimized visibility on production lines
-
_1.jpg)
IK08 Impact-Resistant Housing
-
.png)
A full Dialux simulation for precise planning
Project Deployment & Installation
The retrofit replaced 220 existing 400–600 W metal-halide/HPS high-bay lamps with 150–200 W HB01 LED fixtures. Engineers re-mapped the layout to ensure even illumination and reduce dark zones — with fixture spacing optimized for 9.5 m ceiling height. Smart zone control was configured so that only active production areas are fully lit, while storage and auxiliary zones run at reduced output or remain off when unoccupied.
.png)
Measured Results After Commissioning
Initial on-site measurements showed a 20% increase in average lux, and illumination uniformity (Emin/Eavg) rose from 0.50 to 0.68. Energy use for lighting dropped by approximately 66%, and the facility’s monthly lighting electricity bill fell accordingly. Over 12 months, no LED light replacements were needed; maintenance is now limited to an annual inspection.
-
Energy Savings
48% lower power consumption. Better, uniform lighting improved visual inspection accuracy — line defect rejection rate fell by 22%.
-
.png)
Maintenance Reduction
Over 12 months of continuous operation, none of the 180 HB01 units required maintenance or experienced corrosion, thanks to durable ceramic LED modules and IP67/IP69K housing that withstand harsh chemical vapors.
-
Improved Visibility
Improved workstation visibility, reducing shadows, and enhancing worker safety. Flicker-free and stable illumination reduced eye fatigue complaints by 47%, and worker absenteeism during night shift decreased by 15%.
-
.png)
Corrosion Resistance
Zero corrosion failures after 12 months of continuous operation in a chemically aggressive environment, demonstrating the long-term reliability of the HB01.
-
Operational & Cost Benefits
The upgrade significantly reduced power consumption and maintenance workload, improving production environment, worker comfort, and long-term operational stability. The ROI is projected at 1.5–2.5 years, after which the savings contribute directly to net profit.
Sustainability & Future Lighting Strategy
Encouraged by the success, plant management plans to adopt motion-sensor zoning in low-activity areas (storage, assembly staging) to further cut lighting energy by 15–20%. This retrofit demonstrates that industrial LED upgrades not only reduce costs but support corporate sustainability goals and lower carbon footprint.
Customer Testimonial
“The HB01 LED high bay lights performed flawlessly even in areas with heavy chemical vapor. This upgrade has significantly reduced energy and maintenance costs.”
— Jianhua, Operations Director
 (1).png)
Product Recommendation
The Ceramiclite HB01 industrial LED high bay light delivers high-bay lighting built for demanding industrial environments. With powerful output, precision optics, and a durable IP66 design, it ensures bright, uniform illumination while dramatically cutting energy and maintenance costs.
