U.S. industrial manufacturers control what is considered to be the single largest
market for energy-efficient upgrades, so it’s good news when a major company
announces its efforts to reduce energy consumption.
And when a company is itself directly involved in the production and marketing
of energy-saving products, a case history underscores the extensive opportunities
for selling Green Electrical solutions.
One example is the ABB plant in New Berlin, Wisconsin, which produces the company’s
adjustable low-voltage motor drives.
The factory at ABB’s campus in New Berlin has reduced energy consumption by
at least 25% per year, thanks to a retrofit of lighting in the main office and
production facility. The reduction results from re-bulbing 927 lights in the
56,000-square-feet office space, and the replacement of 350 existing metal halide
lights with new, more efficient fluorescent lights in the 95,000-square-feet
factory.
In 2007, ABB’s global sustainability team requested that each ABB location
reduce its energy consumption by 5%. “After doing research and finding that
40% of all fossil fuels are used to generate electricity, it seemed like lighting,
which we cannot be without, was the logical place to start,” noted Jerry Ulatowski,
facilities manager.
ABB New Berlin began by modifying all of the office fluorescent fixtures –
more than 927 units in all – with electronic ballasts and more economical T8
fluorescent bulbs. This earned the company a $7,400 energy rebate from the local
utility, and resulted in $12,000 annual savings, which are ongoing.
After the process of reviewing, planning, and bidding, an extensive plan was
approved to replace all the lights in the factory. “The factory has changed
a lot since we moved into the building approximately 25 years ago,” said Ulatowski.
“Through our ongoing Operational Excellence program, and the many Kaizen and
LEAN events, the factory has a vastly improved layout that has increased our
capacity dramatically. We realized that not only does the lighting need to reflect
that change, but updating it was a very practical way to support our sustainability
objectives.”
To eliminate impact on production it was decided that the lights would be installed
during third shift. The five-man team from electrical contractor Pieper Electric
worked to replace each of the 350 lights over a period of 7 days, installing
up to 50 lights per night.
The existing metal halide lights were over 25 years old and were original to
the building. Due to their dome shape, they had uneven light distribution, which
created hot-spots, glare, and harsh shadows. In addition, their magnetic components
would expand and contract over time, causing a loud, continuous buzzing sound.
These were replaced with linear fluorescent fixtures using six 54 watt bulbs.
The upgraded lights are controlled electronically, which eliminates any chance
of buzzing, and they provide more ambient light, which is distributed evenly,
and eliminate the disadvantages of halide fixtures.
ABB’s Ken Graber reported that the new fixtures provide more “natural” light,
similar to daylight. Employees assembling drives and working in repair and training
throughout the factory have experienced important benefits. The new lighting
reduces worker eye strain and has positively improved employee mood and productivity.
The more consistent and even distribution of light also helps reduce quality
issues on the manufacturing floor, because work areas are illuminated evenly.
However, the clearest benefit of all is cost savings, both realized and unrealized.
The retrofit achieves $23,300 in energy savings per year – an 18% reduction
in the energy used to power factory lights. And each light fixture carried with
it a $90 rebate from local energy supplier Wisconsin Electric Company. ABB New
Berlin received a $21,800 rebate, once the installation was completed.
Bottom line: ABB’s plant energy savings, plus utility rebate, calculated to
a payback period of two years! In addition, unrealized savings include cooling-cost
savings, due to the reduction of heat produced by the fixtures, reduction of
peak-demand surcharges, and reduction in maintenance costs. The New Berlin facility
upgrade also delivers a reduction of 193 tons of CO2 per year.