Case Study:
LED Instead of Xenon – A Low-Maintenance Lighting Solution for Inline Inspection
From Xenon to LED: Less Maintenance for Inline Inspection
An OEM light source ready for mass production in two months—compact, integrated, and requiring less maintenance during operation
The customer was looking for a low-maintenance alternative to the multi-part xenon system that would be easier to integrate for inspecting its PMMA film. Based on proven technology, we developed a rotatable VIS-LED OEM light source with the required illumination output. In just two months, we created a production-ready solution—including a pilot production run—that required significantly less maintenance and integration effort.
Results at a Glance
This LED solution simplifies integration and service, reduces maintenance and process downtime, and thus lays the foundation for more cost-effective operation of the inspection system.
Longer service life
by switching from xenon to LED
2 months
until it is ready for mass production
360°
horizontally rotatable
120 W instead of 300 W
Supply Capacity
LED module
can be replaced by the customer
1 compact unit
instead of a multi-part system
Cost Comparison: Xenon vs. LED
The LED OEM solution reduces both the initial investment in the system and the ongoing costs for the light source.
System
Cost factor
Xenon System
LED OEM Solution
Total system costs
Xenon System
€6,500
, including lamp
LED OEM Solution
€5,150
, including LED module
Savings from the LED OEM solution
€1,350 / 21%
Light bulbs
Cost of Light Bulbs
Xenon System
458 €
per xenon lamp
LED OEM Solution
550 €
per LED module
Average Lifespan of the Light Source
Xenon System
approx. 2,000 h*
LED OEM Solution
approx. 30,000 h
Lighting supply:
per system per year*
(1 year = 8,766 h)
Xenon System
€2,015
Average of 4.4 lamps per year
LED OEM Solution
165 €
Average of 0.3 modules per year
Cost Savings Through an LED OEM Solution
€1,850 / 92% per year
+
reduced litigation costs
by reducing the number of lamp replacements and maintenance
ROI
ROI < 2 years
Total savings per LED OEM solution per year = 3,200 €
* Typical comparative value for xenon lamps; actual service life depends on the lamp type and operating conditions
190 xenon lamps in 10 years—that’s how many replacement lamps the customer actually purchased for the old systems, clear evidence of the high replacement and maintenance requirements of the previous solution.
The Challenge
The regular replacement of xenon lamps led to process interruptions and ongoing service costs. At the same time, the multi-part system design—consisting of a light source, ballast/igniter, and high-current connection—made integration a complex process. The customer was looking for a streamlined LED solution with comparable lighting performance and significantly easier handling.
The Solution
Based on proven technology, we developed a custom high-power VIS LED light source. An easily integrable, directly mains-powered unit replaces the multi-part xenon system, thereby reducing the number of components, cabling, and integration effort. The replaceable LED module further simplifies maintenance and service. We handled the entire OEM adaptation process—from design and thermal analysis through prototyping and testing to validation and transition to series production.
Benefits for the Customer
Fewer process interruptions due to the elimination of regular xenon lamp replacements
A single-piece system instead of a multi-piece xenon solution
Easier integration thanks to fewer components, cables, and interfaces
Easier maintenance thanks to customer-replaceable LED modules
Technical Implementation
LED Technology Instead of Xenon
120 W LED power
Compact modular design for easier integration into the existing system
LED module that can be replaced by the customer
Direct grid connection without an external ballast or igniter and a high-current connection
Want to extend the life of your existing system?
With a custom-designed LED module, we bring proven applications up to the latest technical standards.
