5 Things Manufacturers Should Know About New Lighting Standards

Making lighting changes to their manufacturing plants and front offices sooner rather than later will help manufacturers to capitalize on as many financial incentives as possible and to realize maximum energy savings.

As part of a global initiative for responsible energy use and conservation, Congress has passed multiple rounds of legislation addressing the energy efficiency of lighting fixtures, ballasts, and lamps (light bulbs and fluorescent tubes) over the past several years. Recent federal legislation includes the 2005 Energy Policy Act (EPAct) and the 2007 Energy Independence and Security Act
(EISA)–new lighting standards.

Certain types of ballasts and high-wattage reflector lamps already have been phased out and have not been produced since as long ago as 2008. In 2012 the U.S. Department of Energy (DOE) will begin enforcing the first phase of the most noticeable changes yet—a gradual halt in the production of incandescent A-line lamps, as well as many inefficient linear fluorescent and halogen parabolic
aluminized reflector (PAR) lamps.

While changes in the lighting industry have been in the works for some time now, many people are still uninformed about the impending shift in the way we illuminate the world. In fact, the results of a recent lighting manufacturer survey show that as many as 65 percent of consumers are unaware of the new lighting standards effective in 2012.

Residential consumers are not the only ones who will be affected by new regulations. According to the DOE and the U.S. Environmental Protection Agency (EPA), lighting in industrial and commercial buildings accounts for close to 71 percent of overall lighting electricity use in the U.S. and consumes nearly 35 percent of the electricity used in the nation’s commercial buildings. Clearly, these changes in lighting regulations are of significant importance to businesses as well as residences.

1. Why are lighting efficiency standards changing?

The movement toward more efficient lighting is a global effort. The European Union, Canada, Mexico, Argentina, Korea, Taiwan, and Japan are among the countries phasing out older lighting technology in favor of less wasteful, more cost-effective alternatives.

Many of the traditional lighting technologies have been around for a long time: The first incandescent lamp was invented in 1879, and the last major innovation in this basic technology was the invention of the tungsten filament in 1910. Tubular-shaped fluorescent lamps were invented more recently than that, but even T12 linear fluorescent lamps have been in production since the 1940s.

As a result of the widespread continuation of these “legacy” lighting products, newer technologies that produce significantly more lumens per watt of electricity have been overlooked in favor of more familiar, less advanced lamps.

2. Which legacy lighting technologies will be affected by the new regulations?

Figure 1
A-line lamps, which will be taken out of production over the next three years, can be substituted easily with screw-in LEDs (shown).

The transition from less efficient to more efficient lighting technologies will focus on three main lamp types: incandescent A-line, linear fluorescent, and halogen PAR lamps.

Incandescent A-line Lamps. EISA regulations require all A-line lamps to increase lumen production per watt of energy consumed, and standard 100-, 75-, 60-, and 40-W incandescent A-line lamps will be taken out of production gradually over the next three years (see Figure 1). Decorative and specialty incandescent lamps, such as 3-way, generally will be exempted, but the
traditional lamps most people are used to seeing will gradually stop being made.

T12 Linear Fluorescent Tubes. Many types of linear fluorescent tubes will be eliminated under DOE regulations, including nearly all tubular-shaped T12 fluorescent lamps. These lamps are still used for overhead lighting in warehouses and other industrial, institutional, and commercial buildings. Those T12 lamps that will be mostly phased out include:

• 4-foot-long, 11⁄2-inch-diameter,medium bipin
• Many 8-ft.-long, single-pin Slimline
• Many 8-ft.-long, 800 milliamp high-output
• Medium bipin U-6 and U-3

The electromagnetic ballasts that are most commonly used for 4-ft.- and 8-ft.-long T12 fluorescent systems have not been manufactured for sale in the U.S. since July 2010. Thus, manufacturers currently using conventional T12 fluorescent systems will need to modernize their systems soon.

T8 Linear Fluorescent Lamps. Another type of linear fluorescent lighting affected by new lighting efficiency standards is the T8 fluorescent tube (see Figure 2). One-in.-dia. T8 tubes are more energy-efficient, generally provide more light output, are longer-lasting, and require less material to produce than T12 tubes. Even so, certain less efficient T8 tubes will cease to be produced in favor of more efficient T8 alternatives under the new regulations. Examples of T8 fluorescent tubes that will be eliminated include:

• 4-ft.-long, medium bipin 700 series rated at less than 2,850 lumens
• U-6 T8 medium bipin 700 series

All other 4-ft.-long, medium bipin T8s; 800 series medium bipin U-6 T8 lamps; and nearly all 8-ft.-long, high-output T8 lamps and 8-ft.-long, single-pin Slimline T8 lamps meet the regulations and still will be manufactured.

Halogen PAR Lamps. The final type of lamps to be phased out by the new efficiency standards are standard halogen PAR20, PAR30, and PAR38 lamps. These are most often found in track lighting, downlighting, and merchandise-illumination fixtures. For the most part, none of the standard halogen PAR lamps will be manufactured under the new regulations, although inventory will continue to be available in the marketplace until it is depleted.

Manufacturing purchasing agents can substitute the more efficient halogen-IR PAR lamps or LED PAR lamps (see Figure 3).

3. When will the lamps cease to be produced?

All of the countries making the switch to more efficient lighting practices have developed their own timelines for the elimination of inefficient illumination technologies. In the U.S., the 100-W A-line incandescent lamp will no longer be manufactured beginning in January 2012. Manufacturing of the affected halogen PAR lamps and linear fluorescent lighting will halt in July 2012.

4. What alternatives exist for replacing phased-out lighting products?

Figure 3
Halogen-IR PAR lamps that have infrared (IR) coatings on the filament tube and LED PAR lamps (shown) are easy replacements for the discontinued halogen PAR lamps.

Linear Fluorescent Lamps. Most of the T12 and standard T8 fluorescent tubes that will be eliminated can be replaced with more efficient T8 lamps equipped with electronic ballasts. These alternatives are up to 40 percent more energy-efficient than the eliminated products, last longer, and offer better color. T8 tubes are thinner and are produced using less material than T12 tubes, which reduces
environmental impact and allows for simpler transportation, storage, and disposal. Four-ft.-long T8 tubes that meet the new regulatory standards are already commercially available.

Halogen PAR Lamps. Energy-efficient halogen PAR lamps that meet regulatory requirements are commercially available, and other halogen PAR alternatives are currently being developed. The IR coatings on the filament tube of halogen-IR PAR lamps redirects wasted heat emitted by the lamp filament to produce more light without increasing wattage. This yields a 30 percent energy savings over older halogen PAR technologies.

LED Lamps. Revolutionary LED lamp technologies have applications far beyond being A-line incandescent lamp or PAR lamp replacements. LEDs offer a longer life and increased energy savings over other technologies.

LEDs are being used in many industrial and commercial settings, and their acceptance will increase as costs decrease in the coming years.

5. How can a manufacturer benefit most from new lighting efficiency standards?

While new mandates can seem intimidating, well-informed manufacturers stand to gain from the new lighting efficiency standards. While the upfront cost of new lighting technology may seem prohibitive, it is important to consider that 90 percent of the cost of operating a lighting system is the energy it consumes. Therefore, the savings from decreased energy usage, maintenance, and disposal often far outweigh the cost of new lighting.

In addition to the significant energy cost reductions the more efficient technology will bring, facilities also may realize significant savings from reduced maintenance costs because longer-lasting lamps require less frequent replacement. In addition, part of the 2005 EPAct was the Energy Efficient Commercial Buildings Deduction that allows building owners to accelerate the deduction on the cost of energy-efficient lighting or building upgrades, subject to a cap, in the year the equipment is placed in service.

According to the DOE, qualifying buildings that improve their lighting energy efficiency (in watts per square foot) at least 25 to 40 percent over the requirements stated in the 2001 ASHRAE/IESNA 90.1 building energy code can earn an accelerated tax deduction of 30.30 to 30.60 per square foot. Both deductions are available through 2013 for building efficiency projects. A tax adviser can advise about specific situations.

Making lighting changes to their plants and front offices sooner rather than later will help manufacturers to capitalize on as many financial incentives as possible and to realize maximum energy savings.

Understanding the types of lamps and lighting fixtures being used at a facility is important to laying out a plan for incremental, quick-savings upgrades. If a manufacturer decides to retrofit its facility, working with a specialist to maximize energy savings, utility rebates, and government incentives is advised.

Finally, updating the lighting in a facility can be a first step toward achieving Leadership in Energy and Environmental Design (LEED®) certification; qualifying for accelerated tax deductions; and receiving recognition as a sustainable, responsible business.