Sustainable Solutions: Contact Lens Manufacturer Embraces Solar Power to Ensure Operations ResilienceCalifornia-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. The project was designed, installed, and will be maintained by solar contractor ReVamp Energy, which incorporated battery energy storage into the microgrid. The system includes a 780 kW rooftop array with SolarEdge DC-optimized inverters, as well as 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 incurred by spoiled production runs that can occur during power outages. Jay Cutting, president of ReVamp Energy, highlighted the importance of uninterrupted power for the manufacturing process, stating that any reduction in power can ruin an entire production run. To ensure continuous production, excess solar production will be stored in a 450 kW battery, providing backup power for up to 24 hours. The microgrid also includes a generator for added reliability. ReVamp Energy has implemented a custom-made switchgear that automatically switches the energy supply to backup power in case 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 role in achieving high energy production, reliability, and intelligent control. He emphasized the use of power optimizers to maximize solar power generation and the generation of detailed performance data to operate and maintain the microgrid efficiently.

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