Production of LED lamps: business feasibility + classification of lamps + registration entrepreneurial activity+ production technology + equipment + choosing premises and hiring personnel + purchasing raw materials for production + calculating the volume of capital investments and profitability of the business.
Organizing a profitable and competitive business in Russia is not an easy task, especially since many profitable niches for business are already crowded with entrepreneurs.
But in fact, today there are several more promising areas that many budding entrepreneurs have not yet had time to pay attention to. And one of these business ideas is the production of LED lamps, the popularity of which is growing every year.
This type of business, of course, requires significant investment, but in the ranking of promising areas for doing business, such production occupies a leading position.
Why exactly lamps, and how to start your own production? We will talk about all this in this article.
Relevance of the LED lighting businessLED lamps and luminaires are lighting devices that allow us to obtain lighting using LEDs.
Such devices, known for their efficiency and environmental friendliness, have been popular for many years, and experts believe that the demand for LED lamps will still grow.
By the way, this is also facilitated by government regulations that are aimed at saving energy and increasing energy efficiency by eliminating the use of standard incandescent lamps ( https://www.consultant.ru/document/cons_doc_LAW_93978)
Thanks to their production technology, such lamps can be used in industrial areas, in street lighting, and for furnishing residential buildings.
The only disadvantage of producing LED lamps is the need to invest an impressive starting capital for organizing a business. But on the other hand, in view high demand, such a business pays off within 2-3 years and has a profitability of up to 100%.
The reasons for such high demand among the population are obvious, and all thanks to the large number of advantages of LED lamps:
- Safety of lighting devices due to the non-use of mercury in the production of lamps.
- Energy savings reaching 80-90%.
- Long service life.
- No heating due to low heat transfer.
Even with a cursory analysis of all types of lighting lamps, it is easy to understand why LED lamps have a much greater chance of success than other types of lighting devices.
Having analyzed such a large number positive characteristics, we can safely say that the production of LED lamps is.
What kind of LED lamps can be produced? Given the large number of areas in which LED lamps can be used, before starting production you will need to immediately decide on the type of device that you want to produce.Of course, no one forbids producing several types of lamps at once, but it should be understood that the wider the range, the greater the starting capital required.
Therefore, it is much more rational to start by establishing the production of one type, and then increase the scale of the business.
So, you can produce the following options for LED lamps:
- illumination of building facades,
- pool lighting,
- street lights,
- illuminated advertising.
- ceiling,
- wall,
- furniture.
Today, a large number of lamp models have already been created that are in demand, but it cannot be said that there are any mandatory design standards by which lighting products must be created.
Therefore, if you want to enter the market not only with the right, but also a very competitive business, you can develop your own unique model of LED lamp, which will become the “face” of your production.
Often, to create unusual products in this area, novice entrepreneurs resort to consulting engineers who can help with the development of a unique product.
The main thing is, before you go for help, decide what kind of LED lamp you plan to start producing.
LED lamps, production: 2 main ways to organize a business and details about the technological process
An LED lighting business can be started in different ways. There are two main ways to organize such a business, each of which has its own significant advantages and disadvantages.
The full production cycle of LED lamps assumes that your company will not only produce lighting devices, but will also independently produce (grow) crystals to create lamps.
This option leads to the fact that you will be able to produce high-quality products, since the full cycle of creating a lamp will take place before your eyes.
But growing crystals and creating a product “from scratch” is not only a lengthy process, but also a very knowledge-intensive process that cannot be handled by a person without specialized education.
In addition, in Russia there are not many opportunities for organizing this kind of production.
This method is more suitable for those who want to produce LED lamps that will be sold to companies that assemble the lamps themselves.
Method 2. Production of lamps from already supplied materials. If you want to produce LED lamps, then this option is the most rational. Firstly, you don’t need scientists who will set up a complex technological process, and secondly, purchasing ready-made raw materials is faster and easier.If you also purchase a productive line of equipment that can minimize manual labor, then production will be able to pay off faster.
It turns out that the second option is more suitable for organizing the production of LED lamps in Russia, but due to the purchase of materials it will be more expensive, although less complex.
Therefore, as an example, we will consider the last production method, in which you purchase all the necessary raw materials and assemble them into a finished lamp for further sale.
The LED lamp manufacturing technology is schematically as follows:
The above diagram is generalized, since regardless of the type of LED lighting device, a large number technological processes will remain unchanged.
In more detail, the production technology of such lamps consists of the following stages:
| 1. | The first stage of assembling an LED lamp is the installation of crystals using heat-conducting glue. It is carried out using a specialized equipment line, to which the crystals are fed in the form of plates on adhesive tape. |
| 2. | After the crystal is attached, the machine checks the quality of the elements and cuts the tape at in the right place. After the glue has hardened, it is important to check whether the crystals are correctly and securely attached to the tape. |
| 3. | Due to the use of sapphire substrates, further operations with the future lamp are impossible until the elements are coated with a phosphor - a composition that will subsequently provide the characteristic white light of the lamp. |
| 4. | Next, the already “mounted” crystal must be attached to the board along with the power supply elements. This is done using a blowtorch. |
| 5. | Now the boards can be mounted directly into the lamp, after which they must be checked to make sure they are working properly. |
To visualize everything that has been said, pay attention to the schematic representation of the LED:
Before starting your own entrepreneurial activity, it is not enough to just draw up a business plan for your future enterprise. This very enterprise still needs to be legalized, that is, registered. Otherwise, all actions taken will be illegal.
There are 2 ways to legitimize your business - ( individual) or LLC (legal entity).
In order to start production, registering an individual entrepreneur may be enough for you, but only if you are planning a small enterprise. If you dream of developing a large-scale business, you will need to register as a Limited Liability Company.
This is somewhat more difficult to do than in the situation of registering an individual entrepreneur. But in order to open a truly competitive business in this area, this is necessary.
LLC registration begins with the collection necessary documentation and submitting it to the authorized body - the Tax Service.
In order to submit documents, prepare the following list:
- Application on form P11001.
- The founder’s decision to create an LLC – if there is only one founder. Minutes of the meeting of participants - if there are several founders.
- LLC Charter.
- Application for transition to a simplified taxation system - it is most suitable for conducting such activities.
- Receipt for payment of state duty (4 thousand rubles)
By the way, you will also need to pay a certain amount for the legal registration of an LLC, which is not limited only to the cost of the state duty of 4 thousand rubles. You will also have to spend on the formation authorized capital, creating a seal, paying for notary services and opening a bank account.
You will also need to select your activity code according to OKVED. In this case, you should select code number 27.4.
After passing state registration, you will also need to contact the fire and sanitary departments in order to obtain all the necessary permits for your premises.
In addition, you will need to obtain a quality certificate for the manufactured products. To do this, you will need to visit the standardization and certification department.
Equipment and components for the production of LED lamps
To start any production, in addition to knowledge of technological processes, it is also necessary to purchase equipment and components in order.
In the production of lighting fixtures, 2 manufacturing options are often used - automated and manual:
- The first option will be optimal if you decide to use a minimum number of employees and recoup the enterprise as soon as possible.
- The second option involves hiring more employees, but reducing equipment costs. This option is best suited for organizing small production capacity.
Since we are analyzing the organization of a more modern and large enterprise, then, accordingly, we will need automated equipment.
The automated line will allow producing from 1 to 10 thousand lamps per shift, although 5 thousand units of production is already good option to start.
So, you will need the following mandatory equipment to complete the production workshop: LED lamps:
| Automatic assembly of semiconductor elements | 1 400 000 |  |
| Soldering iron | 1 000 |  |
| Stand for checking the quality of LEDs and lamps | 5 000 |
In addition to the equipment for producing the lamps themselves, you also need to think about where you will get the housings for the lamps. You can buy them ready-made, which will allow you to quickly create products, or you can make them yourself.
Creating your own housings may be necessary especially in cases where you decide to produce lamps of unusual shape. However, such equipment for the production of cases is very expensive, and it will not be easy to independently organize an entire workshop for the production of cases.
Moreover, you will need a lot of devices:
- stamping machine,
- apparatus for drawing glass products,
- special machine,
- gas oven.
Therefore, of course, the optimal solution would be to order ready-made housings, which will reduce the cost of purchasing equipment and allow the enterprise to pay for itself faster.
It is important to order cases in bulk - this way you can save a little.
As for the components for the manufacture of lighting devices, it is not difficult to find manufacturers of housings in Russia, but it is still better to look for components for lamps abroad.
You will need the following resources:
| Cases |  |
| Aluminum boards |  |
| Drivers for matrices |  |
| LED Drivers |
When choosing suppliers for the purchase of components, please note: special attention to Japanese and Chinese product manufacturers, such as:
- Chimei.
- Cree Epistar.
- Bridgelux.
To organize production facilities for the manufacture of lighting fixtures of this type, you will need a fairly large room where you can zone the space by selecting several workshops.
Thus, to start such a business, you need to find and rent premises with an area of at least 3 thousand square meters. m.
In it you will highlight the workshops:
- For the production of lamps.
- For assembling ready-made lamps.
- For product packaging.
Also, do not forget about storage facilities and staff rooms.
But renting a large area is not all. Since we are talking about the manufacture of very fragile and standardized products, it will be necessary to carry out major renovation premises, because most often you can find such a large area on the territory of old factories, where there are absolutely no conditions for organizing such a business.
As a result, the premises for the production of LED lamps should:
- have a good ventilation system, especially in the workshop where the lamps will be produced.
- Comply with all sanitary and hygienic standards.
- Maintain under sterile conditions.
The requirements of the sanitary and epidemiological service and standardization and certification bodies for this type of enterprise are very extensive. Don't forget about this when preparing the premises for launch.
What kind of staff will be required and what is the best way to sell finished products?
Since we are considering the type of production organization in which the line is almost completely automated, you will not need a large staff to start a business.
You will need to hire about 10-12 employees who can monitor the equipment and perform other actions.
Your staff must have the following personnel:
- Shop workers – 6 people.
- Serviceman and chief technologist– 1 person.
- Loaders – 2 people.
- Raw material purchasing manager – 1 person.
- Accountant – 1 person.
- Marketer – 1 person.
At the same time, the wages of your employees should not be lower than 25 thousand rubles. per month, since all the actions they perform are very important, and the work of any of them cannot be underestimated.
It is especially important to hire an accountant and marketer at the development stage. The first one will keep all the documentation and will be able to help with organizing the business, which is especially necessary when it comes to a long-term paying off business. The second will be responsible for searching and establishing sales channels, which is very important for a newly opened enterprise.
To sell products, your company will rationally cooperate not only with retail and wholesale stores, but also with industrial enterprises, which are also in great need of lighting equipment.
You definitely need to develop your own website on which you will present your devices, as well as advertise.
Production of LED lamps and lamps.
What stages does the technological process consist of?
When will the production of LED lamps pay off: investment and future profits
As we said at the very beginning, this production is not one of those types of business activities that do not require large investments. On the contrary, due to the high cost of equipment and the need to rent and equip a large premises, such a business requires significant financial costs.
Let's analyze exactly how much money you will need to invest to start a business:
| 1. Registration of business activities | Payment of authorized capital. | 10 thousand rubles. |
| State duty for registering an LLC. | 4 thousand rubles. | |
| Payment for notary services for certification of documents. | 2 thousand rubles. | |
| Making a seal. | 1 thousand rub. | |
| Opening a bank account. | 2 thousand rubles. | |
| 2. Purchase of equipment | 1.5 million rubles. | |
| 3. Purchase of components | 500 thousand rubles. | |
| 4. Rent of premises (including payment of rent for several months in advance) | 1 million rub. | |
| 5. Repair and preparation of premises for production | 1 million rub. | |
| 6. Payment wages staff | 300 thousand rubles. | |
| 7. Other expenses (for advertising, packaging, etc.) | 600 thousand rubles. | |
Ultimately, you will need a fairly large amount of startup investment to make LED lights. Production requires an investment of at least 5 million rubles.
The amount is indeed very impressive, and often for such investments you will have to take out a loan, since it is unlikely that you will be able to afford it right away. In addition, the state does not foresee any assistance programs for the organization of such production facilities.
But due to the fact that this business idea is really used in great demand among the population, it can be calculated that when producing 1 thousand lamps per shift, it will be possible to fully recoup the enterprise in about 2 years, because the average monthly revenue can be from 350 thousand rubles.
At the same time, the expected profitability of the business is 100%.
As a result, we can safely say that the production of LED lamps is indeed a very profitable business, which after 2-3 years of work can not only pay off, but also bring a good profit to its owner.
Such a business is in demand, it is in demand among the population, which means it will be successful for many more decades. And the fact that this niche in Russia is not yet crowded with competitors makes this business idea many times more promising.
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This article is about LED lamps of very low quality - about who produces such LED lamps, how and why. Analysis of market problems. All photographs given in the article illustrate how not to make LED lamps.
WITHToday we will talk about unusual LED lamps. Our guest is Alexander Polishchuk. The man is quite inconspicuous in the lighting engineering market, but no less interesting for that. Our first interview with him about LED lamps took place back in 2009, as part of the online magazine “Shop Light”. To say that it has affected some manufacturers would be an understatement. The process of highly cultural intellectual mutual exchange of opinions, filled to the brim with mutual respect of the interlocutors for each other, lasted several weeks. They demanded refutations, added comments from experts to the article itself... In a word, the echo of what was published circulated around the Internet for a long time. Has much changed in the market since then? Read about this in Alexander Gennadievich’s interview with Lumen&ExpertUnion magazine.
- Hello. Of course, a lot has changed. Remember the end of that interview? When there was no one in this market and I said that Russian companies producing LED lamps have only one option - try at least something, but do it, don’t stop. Apparently, everyone heard me, because the unimaginable began to happen: now shoe sellers, sellers of electric meters, water flow sensors and who knows what else have joined the manufacturers of LED lamps. In a word, inadequate and irresponsible people poured here. Let’s take, for example, LED lamps like “Armstrong” - now only the lazy don’t produce them, and like in the Wild West, they have begun to kill the market.
Our people are not yet accustomed to market relations, to the formation of prices, to goods, and so on. Complete madness began to happen. We thought that they would kill the market in a year and a half.
– What do you mean by “kill”? Maybe they just wanted to make some quick money?“It’s possible, but I’m not sure they succeeded.” Of course, they made some money, but they didn’t have time to skim off the cream. A simple example of what I encountered myself. I arrived at the Moscow “Gormost”. And they tell me: we already have LED lamps hanging. And, although we came for a completely different issue, we still agreed to the excursion. We arrive at the reception area and see these “LED lights”. Naturally, we find out: this is one of the well-known dumping manufacturers, with blue-green LEDs, with a “crushed ice” diffuser - in a word, one manufacturer in the Moscow region. Two thirds or half of the LEDs no longer light up, some have degraded. We ask them “... and how do you like it?” People are spitting. Curtain. What is this? Complete discredit of the LED lighting market. Previously people they grimaced at the words “Chinese LED lamps.” And now we have managed to outdo even China - we not only came up with bullshit, but also launched it into mass production. And so everywhere: in office lighting, in street lighting...
– I propose to talk separately about street LED lamps.– I agree, I’ll give you one more example. State Duma Russian Federation. I go into the locker room, they have LED lights. They are made as follows: LED lamps are inserted into standard Armstrongs to directly replace T8. Blue-cyanotic.
Then we were given a tour of the floors where exactly the same specimens hang. Dear mother! Completely multi-colored, with pixels knocked out somewhere. I ask: “How long do they hang?” They answer: “Six months.” Normal, right? Who needs LED lamps that cannot work for six months!? And all this is served with energy saving sauce.
...thin fiberglass boards with multi-chip LEDs, overclocked to the limit. Question: Why does the LED lamp turn blue after six months? Because he just can't help but turn blue!
When we first started, along with other pioneers in this industry, everyone was focused on a certain economic effect. LED lamps were expensive, we then considered the economic component in order to somehow justify the whole thing. Now the situation is as follows. If we talk about T8 lamps, their fleet in Russia, according to my data, is equal to 9 billion lamps. And in Russia now there are only three large manufacturers fluorescent lamps. In total, they produce about 150 million lamps per year. As an alternative, there are wonderful T5 lamps. Take a classic fluorescent lamp, cheap, with T8 lamps. Its real efficiency is on average approximately 40 lm/W. And T5 already has 60-80. A good, absolutely adequate alternative. Moreover, high-quality light, high-quality lamp, long service life. It costs more, of course, but not exorbitantly.
And the following situation arises. If this is done by the owner, and not by the developer (who needs to deliver anything, hand over the object and forget it), then he has two options: T5 and LEDs. And an LED lamp, which is already economically feasible in comparison with T5, is still very expensive. So, we tested a number of fairly well-known Russian manufacturers, disassembled their lamps and understood why they were bullshit: a steel plate, powder-painted in shagreen, with thin fiberglass boards riveted onto it in humps with multi-chip LEDs, overclocked to the limit. Question: Why does the LED lamp turn blue after six months? Because he just can't help but turn blue!
- Well, well real example can you bring it from life?– Here’s a recent example: the Museum of the Great Patriotic War on Poklonnaya Hill, they are urgently hanging LED lamps there to replace, attention, the new ones that have just been installed. The previous LED lights failed within one working day. And there are plenty of such precedents. In the office of some of our competitors, all their lamps also turned blue within a year.
- Yes, their own. As they themselves admitted, they are simply too lazy to change. And this is everywhere. Everyone is slowly deflating. And everyone started in different ways: some with Nichia, some with MX-6, some with something else. Then, dumping, many switched to brands that do not exist in nature, incomprehensible Chinese production with dubious filling. Even one well-known company that buys Chinese LEDs by weight and passes them off as their own is now taking a break - people are abandoning it because it is so expensive. That is, they find LEDs somewhere at a bargain price! It's complete madness going on.
Their turnover dropped enormously. The dumping is unrealistic - they are trying to sell off the remainder, since they have invested huge sums. And now a similar LED lamp can be bought for one and a half thousand rubles. But this is no longer a lamp at all. It loses not only economic, but also all reasonable expediency, because if you take such a product, then you pursue certain goals - good light, brightness, economy, and not separately, but all together. Plus, you can also get additional options - no glare on the monitor, minimal pulsation and much more. It costs some money.
Another important point is the components of the lamp. You can make a steel lamp and paint it whatever you want without using the housing as a heat sink, and still use high-quality aluminum circuit boards.
– Are we talking about a specific LED lamp?- That's what I do. I use the same boards as in street LED lamps. Same high quality composite material. My board works outdoors, and it doesn’t need a heat sink, I put it on aluminum, and the lamp turns out to last forever. I can upgrade it in any way I want - I can even make a spotlight from this lamp. Because the LED temperature is 35°C at an ambient temperature of 25°C.
I can increase the current to any limit. I have statistics. Since 2008, out of the entire mass of LED lamps I have made, and I have made a lot of them, I have only had one failure. These were Osram LEDs and the failure was due to soldering. Thus, I can safely give a guarantee of over five years. And I made LED lamps in both steel and aluminum cases of different thicknesses. At the very beginning I took Osram, then switched to Cree. At one time I used MX-6 LEDs, knowing full well what was in them. And the chip consumed rated current. I used another LED for boosting. My boards are made in such a way that I can mount any LEDs there, depending on where the LED lamp goes.
And doing all sorts of bullshit is more expensive for yourself, your reputation is more important. Now there is another interesting trend on the market - some people are starting to diversify this business. Some merge with others, because it is simply impossible to sell so much bullshit separately. And let me emphasize once again, all this disgrace began to happen due to the fact that everyone who was not too lazy entered the market. But there were still no specialists in the country. And even Saransk, with two graduations of lighting engineers a year, cannot influence the situation. I have information from a person who stood at the origins of LED lighting technology since the late 80s. According to him, the current situation in the lighting market threatens national security countries, because what is now being installed en masse everywhere is really harmful. And now they are connecting Rospotrebnadzor so that before adoption technical regulations introduce at least temporary protective measures. So that every LED lamp undergoes mandatory certification.
Moreover, I emphasize, it is LED lamps, not LEDs. And comprehensively, and not according to individual parameters such as electromagnetic compatibility. And then it gets ridiculous: some take a window profile (!), put an LED in there, install the cheapest Chinese or Israeli glass, get colossal overall brightness and sell it. And they don’t even evaluate it based on discomfort. And in general, few people in our country know about this indicator. I have an employee, a lighting engineer by training, who spent six months learning to calculate this indicator. This is not what they teach. Although all this is spelled out both in SNiPs and in the new GOST. But no one understands how to calculate it.
An LED lamp, in which the overall brightness is a thousand times greater than permitted, is naturally a source increased danger. And the right LED lamp needs to be made wisely, calculate the indicators of discomfort, and even better, measure it, which no one is doing except one Moscow laboratory. I understand that no one needs this, but when I work with clients, I want to leave only positive emotions, no matter how much this LED lamp is sold for.
Plus, when they slip you an LED lamp, whose spectrum is worse than that of the “lights” - well, what can we talk about here? What about the flicker? What about the ripple factor? At the moment, everyone is chasing power factor correction with direct current conversion. This is the point. Nowadays there are a lot of LED lamps with a pulsation coefficient of 50–70% luminous flux. They're crazy cheap. But they have a good cos f - 0.998. Almost Seoul Semiconductors with their famous Acriche, where the ripple depth is 57% and which is impossible to get rid of.
- Fine. Are there any positive changes?– Unfortunately, the market is still in a stage of uncivilized growth. Naturally, this situation will change someday. Well, for now, here's another example. The situation regarding the Armstrongs is completely clear. All “cool” Western brands like Stockmann use T5 lamps and do not even consider Russian LED lamps.
So, we calculated that for an LED lamp to compete with T5 lamps and at the same time be cost-effective, it should cost about 3.5 thousand rubles. This is based on the minimum dealer markup. When an LED lamp costs 2–2.5 thousand, it is better not to mess with it and calmly hang T5 lamps.
– Yes, but this is the minimum. Moreover, I’m talking about the price not even for the end user, but rather for the dealer. In reality, the lamp should be a little more expensive. But it will pay off. According to my forecasts, made on the basis of the Interlight-2011 exhibition, the Armstrong market will die, because a normal alternative to T8 lamps will appear - a regular LED lamp for replacement in raster luminaires.
- In what sense does it mean “die”?– In the sense of replacing existing lamps with LED “Armstrongs”. With the advent of adequate LED lamps, it would no longer be necessary. Of course, this has not happened yet, but I have already seen these lamps in action. They are not made in Russia. The maximum is to re-stick the labels. They are made by the Chinese. I saw the right lamps a la Philips, they are made by Italians. But they are very expensive and everything is done according to Feng Shui: optical system, housing, proper heat dissipation, normal LEDs. The lamp turns out to be expensive and it is difficult for it to compete with a ready-made LED lamp.
– What can be said about the technology of LED lamps, when many low-power chips are mounted in one housing the length of a lamp, and the whole thing is filled with a layer of phosphor?An expensive technology that has a huge drawback: very large power losses and reduced efficiency. Even one Russian company tried to follow this path. They wanted to make lamps by applying phosphor to glass. The effectiveness was zero. Then Osram made light bulbs, and Cree is also working in this direction. But if you look at their effectiveness, this technology can only fight incandescent lamps so far.
– What about remote phosphor technology?– Yes, MELZ tried to make it at one time. I did R&D with them on this technology, although in 2007. In the end, nothing worked out. They bring me a light bulb, and it glows, but does not shine. They pump current into the blue chips, but to no avail - the losses are huge.
– Yes, but not just a lens in the form in which we present it, but a lens cap. And this is not a banal matte diffuser, which contains crazy losses along with “mixing”, but a whole system. Moreover, we worked with them for a very long time, went through more than 20 options... But now I’m in no hurry with this market. Knowing the trends, I will wait until LED lamps are installed everywhere to replace the “lights” that turn blue and degrade. Then it will be possible to make normal light bulbs.
– OK, it’s clear from the Armstrong-type LED lamps. What is happening now with street LED lighting?– And with the street there is even more chaos. Everyone has forgotten that GOSTs exist. Fans of aggressive marketing were the first to forget about this, and, it seems to me, intentionally. In general, this question cannot be answered so easily. For example, there was a tender in Dmitrov. Everyone who could hang themselves there hung themselves. Even Philips LED lamps hung there. Who won and how is a separate issue. The worst thing is that people don’t even understand what a light intensity curve is. People do not understand the design features of LED lamps, and, in principle, lamps.
And I’m not talking about customers now, but about manufacturers! Take, for example, the notorious “shovels”. These so-called LED lamps were installed, and then snowfalls began. A couple of days - and the mast was bent down. The LED lamp itself weighs about 20 kg, and there is also ice on top, which makes the lighting device twice as heavy.
In a word, everything is very bad so far.
- It's clear. Regarding the form factor and “shovels”: what do you think about LEDs, the so-called “fried eggs”, with one large lens?- A very standard solution. And this is also a separate topic. Essentially, this is a matrix. If we turn the conversation to LEDs, three directions, three global trends, and very interesting ones, are now actively developing. First. Classic of the genre. One square millimeter of a chip, which has now been mastered by everyone, on which they are now achieving fantastic characteristics, which is already coming to its physical level saturation of technology.
It is impossible to achieve high efficiency on large chips. This can only be done on small children.
The second is what Nichia has been promoting all along, and what a wonderful Russian company, having purchased reactors the day before yesterday, is now trying to produce. This is a multi-chip technology, or a matrix based on small chips. The trick is that it is impossible to achieve high efficiency on large chips, and this can only be done on small ones. However, this technology has enormous disadvantages, and everyone knows about it, incl. and the authors of the idea who honestly write about this: “multichips” using packaging technology (and it doesn’t matter whether it’s chip-on-board or something else) have a very small resource. If in a single-chip LED degradation of the phosphor occurs, then in a multi-chip the degradation of the chip itself occurs, which is much worse.
And the third trend, the founder of which can still be considered Osram (remember Platinum Dragon?) This is the technology of, so to speak, huge chips. It also turned out to be not problematic - the larger the area of the chip, the more dislocations there are in it and the lower the efficiency. Those. you pump in quite a lot of current, but the lm/W efficiency you get is low. The first revolution here was carried out by one American company, which showed 2 years ago 100 lm/W on 10 mm 2 chips. It was a song! Then the American LEDEngine tried to show something in this direction, although they specialize in packaging. A very interesting specimen, but terribly expensive.
Now it's all quieted down. Osram also stopped moving in this direction, focusing all its efforts on a normal, waste product. Actually, like Cree. We placed the greatest emphasis on 1-mm 2 chips, on housings, on mass production, on new technologies for applying phosphor and thereby reducing costs.
And then something happened that no one expected. Out of nowhere, Cree announces 9 mm 2 chips, 160 lm/W. This is already a technological revolution. Now let's return to the matrices. These are chips (no matter what size), stuck in large numbers within the LED housing and covered with a single layer of phosphor. They squeeze out 10, 30, 60 W... it doesn’t matter.
The problem is that it is simply impossible to ensure the normal lifespan of such an LED lamp. After all, when we calculate thermal resistance, the formula includes the contact area of the chip with the heat sink. And we get accumulation large quantity heat. I know only one person in Russia who has learned to work with such LEDs, but everything there is based on liquid (!) cooling. Everything else is from the evil one. Please run the antifreeze in a circle and you will get the perfect LED light. No matter what other radiator you take, no matter what you do, you won’t be able to cool it properly.
So, for example, the honest guys from Cree, having made such a matrix, honestly declare a resource of 30 thousand hours per LED lamp or lamp and do not worry. This once again confirms that it is impossible to remove heat normally. Plus, take into account the huge current density combined with this inability to remove heat.
The situation is completely different with the large chips discussed above. A larger crystal can be installed in a case essentially the size of this crystal. Or just Chip-on-board. And you will receive the colossal reliability of an LED lamp. Firstly, there are huge current densities there. And to get 160 lm/W you will be very far from the maximum densities; there is a huge space for a contact system; you can use gold wire of completely different sections; you get direct voltage drops that are unattainable with normal technologies... In my opinion, there are huge prospects here. The technology has just started and it has enormous potential. But there are also problems here: growing structures, obtaining contact systems and much more... On a 100 mm 2 substrate you should get a mono chip with a current density of 1000 A/mm 2.
The honest guys from Cree, having made such a matrix, honestly claim a resource of 30 thousand hours and don’t worry about it. This once again confirms that it is impossible to remove heat normally
And then cut it and turn it into big chips different sizes for different tasks. These are very interesting technologies that dramatically reduce costs and the cost of a lumen. Those. matrices, multichips and millimeter chips began to dramatically lose out to this technology. Again, why? In addition to efficiency and problems with heat dissipation, there is one more feature. Here you take an LED, a matrix. The first is small, the second, of course, is much larger. They are the same in terms of current. But it is possible to collect the light flux from the matrix and form the desired CSS only due to reflection. And tricks with small lenses don't work here. The physical size of the lens is proportional to the square of the area of the luminous body. Those. for a square millimeter of chip, a 10-degree lens, which collects conditionally 100% of the light flux, has a height of 50 mm and a diameter of 40 mm. Now let’s take a matrix with a diameter of 15 mm. We will need a lens 225 times larger.
And here we return to the topic of our conversation. The LED allows you to do whatever you want with it, opening up immense scope for creativity. What is needed is a professional creativity, something we simply don’t have on the market today. Therefore, to the question “What do we have in the market for street LED lamps?” The answer is one word - “Nothing.” Absolutely nothing.
– In one sentence - “Why”?– And because no one knows how to develop LED lamps, everyone copies from the Chinese and from each other.
- Alexander, summarizing our conversation, can you briefly describe the current state of affairs in Russian market LED lights?– Over the past three years, many companies have appeared. Something started to happen, and, as a rule, badly. Corruption was and remains the same, it even intensified, it became impossible to sell, all tenders were paid for. Here we are whole year participated in the tender for Domodedovo, but not a single LED lamp was installed. Because companies that don’t really represent anything win win. And the customer constantly cuts them down. Because he understands that this is complete bullshit. In general, this is politics. And everything here depends on our power. If accepted right decisions, then everything will settle down on the market.
And one more thing - accession to the WTO. China may pour in. Although some forces are now lobbying for an increase in protective duties for them. If the right, good and expensive China comes to us, then we will compete and the market will receive an impetus for development.
And we can kill the market ourselves. To discredit him in such a way that as soon as it affects national security, why the hell will everything be banned. Or they will be handed over to state corporations. That is, there will be official competition, but everyone will be given instructions to buy, for example, only these or those. Which is exactly what we almost came to.
The production of LED lamps does not require large financial costs. For a successful mini-business, you don’t need to buy expensive equipment; you only need consumables, which are what lamps and work crew are made from. Consumables include: circuit boards, LEDs, microcircuits, soldering irons. For example, in China, both large factories and small workshops can produce lamps.
Organization of mini production of LED lamps.
Any self-respecting entrepreneur begins his activities with a business plan. According to statistics, the production of LED lamps consists of: an appropriate premises, usually rented with an area of 300 to 1000 square meters. Mandatory presence of assembly tables for lamp assembly. The number of employees depends on the volume of production; there can be several dozen or more than a hundred workers.
Soldering irons, tin, rosin, fans, showroom - all this will be needed in the process of making lamps. A stand where the quality of the product is checked. As in any enterprise, there must be an office for the head of the workshop and an office for the director. Also a utility room - a warehouse for finished products.
During the first 2 years, production will cover the opening costs of this business. There is one significant disadvantage in the production of LED lamps - cost. labor force. Compared to the Chinese, it is overpriced. In this regard, competition with Chinese manufacturers is very strong, even if you take into account the difference in the cost of delivering goods in Russia or from abroad, you will still be inferior to them.
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Sales of LED lamps.
An important point in mini lamp production is target audience buyers. These could be small private consumers who are getting rid of unprofitable incandescent lamps and switching to LED lamps. Their advantage is long term operation and more beneficial light for the eyes.
As buyers of this product can perform and industrial enterprises. LED lamps are also used in radio engineering. If the business is directed to the production of household and industrial lamps, the profit margin will increase significantly.
LED production options.
The production process can be carried out in two ways: the first is more expensive, the second saves costs. The fact is that the full production cycle entails large financial costs for the purchase of equipment, the purchase of consumables and raw materials. The second method of making lamps is to purchase the component elements and their subsequent packaging.
The production of LED lamps takes place in several stages: processing and installation of chips, packaging and assembly of finished products.
For the mini-production of this product, you will need stamping installations for legs and domes of flasks. You should purchase a splitting machine; it is used to cut and transport the ends of the tubes. In production, you will definitely need a special installation that pulls out glass products, as well as a conveyor with blowing. You cannot do without gas stoves. The listed equipment can be purchased either new or used. The second option will significantly save your costs.
The secret of success in the production of LED lamps.
Pledge successful business consists of properly selected personnel, these should be highly qualified specialists. The number of employees depends on the volume of goods produced. How more quantity production per day, the more workers there should be. Don't forget that your company will need the services of an accountant and marketer. It is also necessary to organize a department of employees for the purchase of consumables and sales of goods. Of course, any production will not be without management personnel: director, deputy director and other positions as necessary.
Video mini production of LED lamps:
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Increased investor interest in the lighting industry for last couple years is associated with the federal law “On energy saving and increasing energy efficiency and on introducing amendments to certain legislative acts of the Russian Federation” signed on November 23, 2009 by Russian President D. Medvedev.
According to this law, from January 1, 2011, incandescent electric lamps with a power of more than 100 W are not allowed for sale, from January 1, 2012 - with a power of 75 W, and from January 1, 2014, incandescent lamps with a power of 25 W or more will be prohibited. The implementation of the state program for the introduction of energy-saving equipment allows us to predict rapid growth in demand for energy-saving lamps in the next few years.
Energy-saving light sources traditionally include compact fluorescent lamps, LEDs (light-emitting diode) and OLEDs (organic light-emitting diodes). Compact fluorescent lamps are not the last word in science. They appeared in the late 1980s and were then significantly superior to older lamps in terms of luminous efficiency and service life.
LED lamps began to be used in general lighting relatively recently. But for a long time there were no white LEDs on the market because a semiconductor material capable of directly producing white light had not yet been invented.
Modern scientists have found optimal solution This problem is the mixing of complementary colors, creating the effect white. The production and sale of LED lamps are considered promising areas for business.
Experts are convinced that building enterprises in our country full cycle production of compact fluorescent lamps does not make sense. In the presence of cheap Chinese components and the absence of specialists in Russia the desired profile, equipment and experience in production, fluorescent lamps domestic producers, most likely, will be more expensive than Chinese ones with relatively the same quality. We also note that our state, unfortunately, is not yet in a hurry to support the domestic lamp industry. In China and in the countries of the European Union there are common government programs helping their producers.
Therefore, despite the fact that there is practically no competition among domestic manufacturers of compact fluorescent lamps, the bulk of the products come from China and are not always different high quality However, marketers still rely on LED lamps.
The latter are more environmentally friendly, since they do not contain mercury, and have a longer service life (from 12 years and above with a 5-year warranty versus 1-2 years of service life of fluorescent lamps). They are superior to LED lamps in other indicators, in particular, energy consumption.
It is quite possible that research data on the beneficial effects of such lamps on human vision will appear in the near future. To be fair, it is worth noting that LEDs are still quite expensive and do not have high power. But, according to experts, achieving optimal parameters is only a matter of time. Already, the cost of LED lamps is significantly lower than what it was a couple of years ago.
Unlike compact fluorescent lamps, the production of LEDs in our country has already been established. The largest players in this market are TELZ, the Svetlana-Optoelktronika plant, OptoGan CJSC and others. In 2010, experts noted a significant increase in the output of LED products Russian enterprises. At least 10 domestic companies planned to master the production of LED lamps last year. Five more companies were at the stage of pilot production of LED lamps.
However, despite this, the domestic LED industry still lags far behind other countries in this area. And this despite the fact that most of the materials for LED lamps can and are produced in Russia (metals, substrates, semiconductor materials, phosphors, especially pure gases). So, taking into account the fact that China does not produce the most powerful LEDs, there are good prospects for the domestic industry to enter the domestic and foreign markets with its own products.
Just a couple of years ago, the share of LEDs in the energy-saving lamps segment was less than 10%. By 2015, experts predict that this gap will narrow: LEDs, in their opinion, should occupy about 30% of the market for environmentally friendly light sources, and fluorescent ones - about 40%. In a few years, LED lamps should overtake obsolete fluorescent light bulbs in popularity. In 2011, the volume of the global LED market is estimated at $9 billion. At the same time, the largest growth is demonstrated by the general lighting segment.
If previously LEDs were used exclusively in radio engineering as indicators and illumination, today household and industrial LED lamps are produced. Depending on the funds you have, you can choose either complete lamp production, which includes all stages from the manufacture of component elements to packaging of finished products, or assembly production of compact LED lamps.
The latter production option does not require the purchase of expensive equipment. Consumables will include circuit boards, microcircuits, LEDs and soldering irons. Several dozen workers at assembly tables are engaged in assembling lamps from all these components.
For the production of LED lamps you will need an area of 3500 sq. m. The premises allocated for assembly shops must be well ventilated.
In addition, a stand for checking product quality, a showroom and storage facilities are required. This production option, which includes only the stages of assembling finished components and packaging lamps, on the one hand, does not require huge investments.
If at the first stage you plan to only assemble LED lamps from ready-made components produced by subcontractors, the volume of required investment will be from 5 million rubles. The internal rate of return (IRR) will be about 130% per annum.
The expected payback period for the project will be from 1 to 2 years. However, this production of LED lamps has one big disadvantage - the cost of labor in our country is incomparably higher than that in China. Therefore, even taking into account the difference in the cost of delivering products in Russia and from abroad, you are unlikely to be able to compete on price with Chinese manufacturers, unless the quality of your products is at a sufficiently high level.
The presence of our own patented technologies for the production of LED lamps, the novelty and relevance of products for the country, established contacts with subcontractors, direct importers and suppliers of components are the main prerequisites for the successful implementation of the project.
Organization of production of LED lampsOrganizing a full-fledged production of LED lamps requires incomparably large funds. In addition to the costs of the premises for the workshop (it can be bought or rented by concluding standard contract rental), you will have to spend money on purchasing equipment.
Creating a full-cycle production of LED products includes several stages: chip processing, installation, packaging, and assembly of finished products.
You will need installations for stamping the legs and domes of flasks, installations for drawing glass products, a breaker machine that cuts and mandrels the ends of tubes, gas furnaces and a conveyor with blowing. You can, of course, save a lot by purchasing equipment of appropriate quality, but used.
Another significant cost item is the search for qualified personnel. Its quantity will depend on the scale of production. For example, when producing several tens of thousands of light bulbs daily, 1.5-2 times more personnel will be required than for a production facility producing a thousand lamps per day.
In addition to production workers, you will also need an accountant to maintain documentation, employees of the purchasing and sales department, marketing specialists, and administrative personnel.
The total investment will be from 100 million rubles. The minimum initial costs for launching full-scale production of energy-saving lamps will be from 15-20 million rubles, and the approximate payback period is from a year or more.
Experts are confident that success in the near future will belong to knowledge-intensive production. In the energy-saving lamp production segment, the prospects for this are very optimistic. So, due to the positive dynamics Russian production LEDs and a sharp increase in imports, the structure of demand for LED products has also changed.
For example, in the period from 2009 to 2010 in total volume imports of LED lamps into Russia increased the share of high-brightness lamps. However, despite such high demand, options for replacing a 100 W incandescent lamp are only available in the segment of obsolete compact fluorescent lamps. But the production of LED lamps to replace incandescent lamps of such brightness does not exist not only in Russia, but also abroad.
The latest achievement in the global LED industry is an industrial prototype for replacing a 90-watt lamp. The commercially available option for LED consumers is an incandescent equivalent of only 75 watts. Of course, scientific developments require large investments, which small businesses cannot afford. However, if you plan to expand in the future own production and access to international market, it is worth thinking about the possibility of conducting scientific research and filing patents for them.
See also: Video about the production of LED lamps
Calculator for calculating the profitability of this business
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If you decide to open your own business related to LED lighting, then you have a direct path to Chinese suppliers. Products such as LEDs, LED strips, tubes, lamps, related electrical appliances, etc. They're not worth anything in China. It’s scary to even imagine how low the cost of these goods is in China. There are several auction sites on the Internet where you can order products from China. At the same time, you can find a partner from China and do business with him. Personal contacts with suppliers will help you purchase products in bulk and even cheaper. Most popular online stores those selling foreign goods are Aliexpress and Ebay. For example, I found a batch on Alliexpree LED strip(50 meters) at a wholesale price of 6289 rubles (see photo).
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