Revolutionizing the Contact Lens Industry: Manufacturer Secures Operations with Cutting-Edge Rooftop Solar TechnologyCalifornia-based contact lens manufacturer, Staar Surgical, is set to save on operational costs and improve production efficiency with the installation of an on-site solar microgrid. The company recently inaugurated a 1.1 MW grid-tied microgrid at its production facility in Lake Forest, California. This rooftop solar array is expected to result in annual electricity bill savings of $325,000, while also providing energy resilience during disruptions to the central utility grid. The microgrid, designed and installed by solar contractor ReVamp Energy, includes battery energy storage and a 780 kW rooftop array coupled with SolarEdge DC-optimized inverters. Additionally, two newly-constructed carports house the remaining capacity of the 1,752 module system, which is projected to reduce Staar Surgical’s electricity costs by approximately 50%. The microgrid will also prevent losses incurred from spoiled production runs caused by power outages. Jay Cutting, president of ReVamp Energy, emphasized the importance of uninterrupted power supply in the manufacturing process of contact lenses, stating that any power reduction lasting more than a few seconds can ruin an entire production run. To ensure backup power, excess solar production will be stored in a 450 kW battery, providing between eight and 24 hours of backup power depending on the facility’s load requirements. The system also includes a generator for added production maintenance. ReVamp Energy has designed custom-made switchgear that automatically switches the site’s energy supply to backup power during outages. 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 and from a single platform. Cutting expressed satisfaction with the use of SolarEdge technology in meeting Staar Surgical’s requirements for high energy production, reliability, and intelligent control. He praised SolarEdge’s power optimizers for maximizing solar array output and generating detailed performance data, enabling efficient and cost-effective operation and maintenance of the entire microgrid.

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