Revolutionizing Contact Lens Manufacturing: How Rooftop Solar Power Ensures Sustainable OperationsCalifornia-based contact lens manufacturer, Staar Surgical, is set to reduce operational costs and enhance the reliability of its operations with the installation of a rooftop solar microgrid. The 1.1 MW grid-tied microgrid, located at the company’s production facility in Lake Forest, is expected to result in annual electricity bill savings of $325,000. In addition to cost savings, the microgrid will provide energy resilience during times when the central utility grid is affected. ReVamp Energy, a solar contractor, designed, installed, and will maintain the microgrid, which includes battery energy storage. The system consists of a 780 kW rooftop array with SolarEdge DC-optimized inverters and additional capacity on two newly-constructed carports. With a total of 1,752 modules, the microgrid is projected to reduce Staar Surgical’s electricity costs by approximately 50%. Furthermore, the company will avoid losses caused by power outages during the manufacturing process, which can lead to spoiled production runs. To address this issue, a 450 kW battery will store excess solar production, providing backup power for up to 24 hours. Additionally, a generator is included to ensure uninterrupted production. The microgrid is equipped with custom-made switchgear that automatically switches the energy supply to backup power in the event of an outage. Staar Surgical and ReVamp Energy can monitor and manage the microgrid through the SolarEdge monitoring platform, tracking key parameters such as solar energy production, consumption, and battery energy levels in real-time. Jay Cutting, president of ReVamp Energy, emphasized the importance of SolarEdge technology in meeting Staar Surgical’s energy production and control requirements. The use of power optimizers and detailed performance data will enable efficient and cost-effective operation and maintenance of the entire microgrid.

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