Revolutionizing Contact Lens Manufacturing: 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, California, 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, along with 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%. Moreover, the microgrid will help prevent losses incurred due to 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 depending on the facility’s load requirements. The system also includes a generator to ensure uninterrupted production. ReVamp Energy has designed custom-made switchgear that automatically switches the site’s energy supply to backup power in the event of an outage. The microgrid is managed through the SolarEdge monitoring platform, allowing Staar Surgical and ReVamp Energy to track key parameters such as solar energy production, consumption, and battery energy levels in real-time from a single platform. Jay Cutting, President of ReVamp Energy, expressed confidence in the project, stating that SolarEdge technology has been instrumental in meeting Staar Surgical’s requirements for high energy production, reliability, and intelligent control. By leveraging power optimizers and generating detailed performance data, the microgrid will be operated and maintained in the most efficient and cost-effective manner possible.

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