December 6, 2024
LED High Bay Recall Highlights Recurring Design Flaw
Second lighting brand in 5 months recalls fixtures due to failed inexpensive plastic pins
NetZero USA, a Georgia-based lighting maker, has issued a voluntary recall of approximately 16,000 High Bay LED light fixtures following reports of fire hazards linked to degraded plastic pins. This announcement, made in cooperation with the U.S. Consumer Product Safety Commission (CPSC), comes five months after a similar recall by Best Lighting Products for the same issue: degraded plastic pins that secure LED boards.
The affected fixtures, manufactured between May 2018 and January 2022, were produced in China and sold through NetZero USA’s distribution network for $100 to $415 per unit. Seven incidents involving loose LED boards catching fire have been reported, though no injuries occurred.
Recurring Problem Exposes Engineering Flaws
This marks the second recall in 2024 involving LED high bay fixtures and plastic pin failures. Best Lighting Products recalled over 700,000 fixtures earlier this year, citing a similar degradation issue. NetZero informed Inside Lighting that there is no direct connection to Best Lighting. However, the shared root cause suggests the possibility of overlapping suppliers, a common Chinese factory, or design similarities.
These incidents highlight the critical nature of design evaluation across all components of a luminaire. Engineering teams often emphasize high-performance components like LED boards, drivers, and lenses, as these directly impact cost and functionality. However, the failure of a low-cost part — such as a plastic pin costing mere cents — can have catastrophic consequences. In this case, degraded pins allowed electrically charged LED boards to detach, creating a fire hazard.
Above: Product label of recalled fixture
The financial and operational impact of such failures is significant. High bay fixtures, typically installed in warehouses or facilities with high ceilings, require lifts or specialized equipment for inspection and repair. This adds logistical complexity and costs, turning a minor material defect into a major liability. Even when covered by insurance, manufacturers must allocate substantial resources to handle recalls, replace defective parts, and rebuild their reputations.
NetZero’s recall, though smaller in scale than Best Lighting’s earlier recall, illustrates the substantial costs associated with addressing such failures. The firm’s decision to proactively redesign the fastening method for post-2022 models may prevent future issues but comes too late for the 16,000 units now subject to recall.
Anthony Meeks, Vice President of Marketing for NetZero, confirmed details of the recall to Inside Lighting, stating:
“Certain NetZero USA® High Bay models manufactured between May 2018 and January 2022 used a plastic fastener to secure the PCB boards to the housing. We have subsequently observed that these fasteners can fail over time in certain applications when the lights are installed in extreme environments. NetZero USA® has taken the proactive step to voluntarily recall all our High Bay products using this fastener.”
Details of the Recall
Consumers are advised to stop using affected fixtures immediately if they observe loose LED boards or discoloration in the lens. Customers can contact NetZero for free inspections, repairs, or replacements. The company is reaching out to known purchasers to schedule corrective action.
The recalled products include models ranging from 110 to 320 watts, commonly used in commercial environments like warehouses. Affected model numbers include NZ 9110.3, NZ 9110.4, NZ-9110.5, NZ 9160.3, 9160.4, NZ 9220.3, NZ 9220.4, NZ 9220.5, NZ 9321.3, NZ9321.3, NZ 9321.4, and NZ 9321.5. These units were sold through distributors between August 2018 and October 2024.
The CPSC notice highlights the risk posed by degraded plastic pins, stating:
“The plastic pins securing the LED light fixture can degrade, allowing the electrically charged LED board to come loose and contact items nearby that can catch fire, posing a fire hazard.”
NetZero has provided contact options for customers seeking more information, including a toll-free number and website. The recall applies to all products using the faulty fasteners, which have since been replaced with a reengineered design.
