Revolutionizing the Contact Lens Industry: Manufacturer Secures Operations with Innovative Rooftop Solar SolutionCalifornia-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, as well as capacity installed on two newly-constructed carports. With a total of 1,752 modules, the microgrid is anticipated to reduce Staar Surgical’s electricity costs by approximately 50%. Moreover, the microgrid will prevent losses incurred from spoiled production runs that can occur during power outages. Jay Cutting, president of ReVamp Energy, emphasized the importance of uninterrupted power for the manufacturing process, stating that any reduction in power could potentially 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 microgrid also includes a generator to maintain production. To manage the microgrid, ReVamp Energy designed custom-made switchgear that automatically switches the site’s energy supply to backup power during outages. The microgrid can be monitored 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 praised SolarEdge technology for its contribution to high energy production, reliability, and intelligent control. He highlighted the use of power optimizers to maximize power output from the solar arrays and the generation of detailed performance data that enables efficient and cost-effective operation and maintenance of the entire microgrid.

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