Revolutionizing the Contact Lens Industry: Manufacturer Secures Future with Solar PowerCalifornia-based contact lens manufacturer, Staar Surgical, is set to reduce operational costs and improve 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 save Staar Surgical $325,000 in annual electricity bills. In addition to cost savings, the microgrid will provide energy resilience during times when the central utility grid is affected. The project was designed, installed, and will be maintained by solar contractor ReVamp Energy, which incorporated battery energy storage into the microgrid. The system consists of a 780 kW rooftop array with SolarEdge DC-optimized inverters, as well as capacity installed on two newly-constructed carports. With a total of 1,752 modules, the microgrid is estimated to reduce the company’s electricity costs by 50%. Furthermore, the microgrid will prevent losses from spoiled production runs that can occur when power outages disrupt the manufacturing process. Jay Cutting, president of ReVamp Energy, emphasized the importance of uninterrupted power for Staar Surgical’s energy-intensive production process. The excess solar production will be stored in a 450 kW battery, providing backup power for up to 24 hours depending on the facility’s load requirements. To ensure continuous production, the system also includes a generator. ReVamp Energy designed custom-made switchgear that automatically switches the site’s energy supply to backup power in the event of an outage. The microgrid can be managed through the SolarEdge monitoring platform, allowing Staar Surgical and ReVamp Energy to track solar energy production, consumption, and battery energy levels in real-time from a single platform. Cutting praised SolarEdge technology for its contribution to high energy production, reliability, and intelligent control. The use of power optimizers maximizes power generation from the solar arrays and provides detailed performance data for efficient and cost-effective operation and maintenance of the entire microgrid.

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