One New Year’s resolution the factory at ABB’s campus in New Berlin already is making good on is reducing energy consumption -- by at least 25% per year -- via a retrofit of lighting in the main office and production facility, alone. The reduction results from rebulbing 927 lights in the 56,000 sq ft office space, and the replacement of 350 existing metal halide lights with new, more efficient fluorescent lights in the 95,000 sq ft factory. The retrofit is just one of many proactive steps the campus has taken to be a smart user of energy.
From Office to Factory
In 2007, ABB’s global sustainability team requested that each ABB location reduce its energy consumption by 5%.
“After doing research and finding that 40% of all fossil fuels are used to generate electricity, it seemed like lighting, which we cannot be without, was the logical place to start,” noted Jerry Ulatowski, facilities manager. ABB New Berlin began by modifying all of the office fluorescent fixtures -- more than 927 units in all -- with electronic ballasts and more economical T8 fluorescent bulbs. This earned the company a $7,400 energy rebate from the local utility, and resulted in $12,000 annual savings, which are ongoing.
After the process of reviewing, planning, and bidding, an extensive plan was approved to replace all the lights in the factory.
“The factory has changed a lot since we moved into the building approximately 25 years ago,” said Ulatowski. “Through our ongoing Operational Excellence program, and the many Kaizen and Lean events, the factory has a vastly improved layout that has increased our capacity dramatically. We realized that not only does the lighting need to reflect that change, but updating it was a very practical way to support our sustainability objectives.”
It was decided that the lights would be installed during third shift, to eliminate any impact on production. Duane Gaglione, manager and lead for third-party electrical contractor Pieper Electric, and his team of five employees would take on the challenge of replacing each of the 350 lights over a period of 7 days, installing up to 50 lights per night.
Metal Halide to Linear Fluorescents
The traditional metal halide lights, original to the building, were over 25 years old. Due to their dome shape, they distributed light unevenly, creating hot-spots, glare, and harsh shadows. In addition, their magnetic components expanded and contracted over time, causing a loud, continuous buzzing sound. The new light fixtures, known as linear fluorescents, include 6 bulbs – 54 watts each. These lights provide more ambient light, evenly distributed, and eliminate the disadvantages of halide fixtures. In addition, the components are controlled electronically, eliminating any chance of buzzing.
Optimum Production Conditions
For employees assembling drives and working in repair and training throughout the factory, the new fixtures provide more “natural” light, similar to daylight. This reduces eye strain and, report employees, affects mood and productivity positively. The more consistent and even distribution of light can also help reduce quality issues, note team leads on the manufacturing floor, because glare on production lines and shadows inside drive cabinets are illuminated evenly.
Energy Savings, Rebate, Reduced CO2
However, the clearest benefit of all is cost savings, both realized and unrealized. The retrofit achieves $23,300 in energy savings per year -- an 18% reduction in the energy used to power factory lights. And each light fixture carries with it a $90 rebate from local energy supplier Wisconsin Electric Company: in total, ABB New Berlin will receive a $21,800 rebate.
These energy savings, plus rebate, add up to a payback period of two years. In total, New Berlin to date is realizing more than 25% in energy savings ($35,300) per year, $29,200 in rebates, and the reduction of 193 tons of CO2 per year.
Additional unrealized savings include cooling-cost savings, due to reduced heat produced by the fixtures; reduction in peak-demand surcharges; and reduction in maintenance costs. Actual energy savings for the factory will be known as utility bills arrive following completion of the retrofit.