Dairy Farm Upgrades to Ceramiclite T8 LED Light

Case Study: Dairy Farm Upgrades to Ceramiclite T8 LED Lights

Background

A large dairy farm in northern China operates multiple milking cow sheds, including a primary barn measuring 372 m × 92.2 m × 3.7 m, divided into 6 rows, each split into two functional zones (feeding lanes, bedding/resting areas, and manure passage zones).

For years, the sheds relied on traditional high-pressure sodium (HPS) and fluorescent fixtures. Over time, the farm faced increasing problems:

LED Lighting Issue

To improve cow comfort, stabilize milk production, and reduce energy and maintenance costs, the farm partnered with Ceramiclite to retrofit the barns with a full LED lighting system.

Uneven Lighting Causing Animal Discomfort

The barn experienced inconsistent illumination along feeding lanes and bedding areas, causing cows to crowd under bright spots and avoid dim sections.
High Electricity Consumption During Long Lighting Cycles

Lighting needed to run nearly 18 hours per day during low-light seasons, resulting in significantly high electricity bills and unnecessary energy waste.
Frequent Lamp Failures in Harsh Barn Conditions

Traditional bulbs and ballasts required replacement every 6–8 months due to the barn’s humid, ammonia-rich environment, increasing maintenance workload and costs.
Excess Heat Output Increasing Ventilation Load

HPS lamps produced substantial heat, pushing the ventilation system to run harder and raising overall operational costs while creating an uncomfortable environment for cattle.

Our Solution & Installation

Ceramiclite designed a barn-specific lighting solution based on the T8 LED Livestock Light (60 W), using insights from environmental conditions, cow behavior, and engineering constraints in dairy barns.

Lighting Design & Layout

From the optical simulation and engineering plan provided:
1). Total lights installed: 660 pcs of Ceramiclite T8 Livestock LED Tubes
2). Layout per zone:2 rows of lights; 33 tubes per row; Total 66 tubes per zone, covering feed alleys + bedding aisles
3). Mounting height: 3.6 m
4). Tube spacing: 4.05 m
5). Distance from light rows to zone edges: 0.6 m
6). Total installed power: approx. 39.6 kW for the full shed
7). Installation accessories: stainless-steel end caps, anti-corrosion suspension rods, IP67/IP69K connectors
Layout Design

Lights were arranged in a grid layout to deliver even illumination along feeding lanes, resting pens, and alleyways. Fixture spacing was set at approximately 4.5 meters to ensure uniform light distribution without dark zones.
Control System

The T8 system is integrated with Ceramiclite’s smart dimming control cabinet, enabling:
1). 0–100% smooth flicker-free dimming
2). Daylight simulation (sunrise → daytime → sunset)
3). Separate zone-based timing
4). Automatic nighttime low-light mode
5). Protection against moisture, dust, and wash-down cleaning routines
Installation Process

The retrofit was completed over two weeks — first removing old HPS fixtures, then installing LED units and rewiring control circuits. No disruption to barn operations was needed as installation was done during low-activity hours.

Why the Ceramiclite T8 LED Barn Light Was Chosen

The farm selected Ceramiclite T8 LED barn lights specifically because they address the typical challenges of cattle sheds:

(1). IP67 / IP69K waterproof rating, resistant to high-pressure and steam wash-down

(2). Ammonia- and acid-resistant construction with PMMA diffuser and stainless steel end caps, IK08 impact protection

(3). Ø75 mm slim profile with uniform, glare-free illumination

(4). Luminous efficacy of 130–150 lm/W

(5). Environmentally friendly, mercury-free, and energy-efficient

(6). Supports multiple dimming options

(7). Easy installation with ceiling-mounted or suspended installation options

(8). More than 5-year warranty
(9). Dimmable Lighting Function:

a). Smooth 0–100% flicker-free dimming across the full range

b). Simulates natural sunrise and sunset cycles, aligning with animals’ circadian rhythms

c). Supports healthy growth and overall animal well-being

Patented Light Spectrum

The patented light spectrum is designed to improve overall animal performance by increasing milk yield, enhancing milk calcium and protein content, shortening calving intervals, and promoting more efficient calcium absorption. With flicker-free operation and no harmful blue light, it also helps strengthen immunity and reduce the incidence of disease.

Results & Observed Improvements

After one full production cycle (≈ 90 days), the farm recorded the following improvements compared with the previous HPS-based lighting:

Testimonial

“The barns look completely different now. The light is even everywhere, and the cows stay much calmer during feeding. The T8 LEDs solved all our dark-corner issues.”

— Shengxi Liu, Barn Manager

“Our electricity bill dropped by almost half. And best of all, no more bulb or ballast failures. The Ceramiclite upgrade paid for itself within just a few months.”

— An Yu, Operations Supervisor

Product Recommendation

T8 LED Light for Livestock Barn

1). Durable, IP66-rated T8 LED barn light built for ammonia-rich, high-humidity livestock environments.
2). Soft, flicker-free illumination reduces animal stress and improves feeding and resting behavior.
3). High efficiency with low heat output helps stabilize barn climate and cut energy costs.
4). Long lifespan and zero-maintenance design keep operations running smoothly.
T16 LED Barn Light

1). Rugged, waterproof T16 LED light engineered for large barns and daily wash-down conditions.
2). Bright, uniform illumination enhances visibility and overall animal welfare.
3). Energy-saving, low-heat LED technology reduces ventilation load and monthly power bills.
4). Reliable long-life performance minimizes maintenance and downtime.