Discover how Lakeshore Die Cast is leveraging solar energy to cut costs, stabilize energy rates, and promote sustainability.
Why Solar Energy Is a Game Changer for Manufacturing
In the manufacturing sector, energy consumption is one of the most substantial operational costs. For companies like Lakeshore Die Cast, which operates powerful 500- to 1,000-ton die cast machines and maneuvers massive steel components, energy efficiency is not just a priority but a necessity. With utility costs projected to rise unpredictably, finding a reliable and cost-effective energy source is crucial.
Solar energy offers a sustainable and economically viable solution. By converting sunlight into electricity, solar power can dramatically lower utility bills and provide long-term rate stability. This transition to solar energy ensures that companies can safeguard cost stability while promoting environmental sustainability, positioning themselves as industry leaders in energy efficiency.
The Implementation Journey: From Concept to Reality
Recognizing the need for a robust energy solution, Lakeshore Die Cast embarked on a journey to integrate solar energy into their operations. The initiative began with the design and installation of a 150kW ground-mounted solar array. This initial project served as a proof of concept to test performance and validate the capabilities of Harvest Solar, the company tasked with implementing the solution.
After achieving promising results with the 150kW system, Lakeshore Die Cast proceeded with a larger 1.5MW ground-mounted array. This phased approach allowed the company to mitigate risks and build confidence in the new energy system. The successful implementation of both solar arrays marked a significant milestone in Lakeshore Die Cast’s journey towards energy independence and sustainability.
Engineering Marvel: Designing Solar Systems for High-Power Demands
Designing a solar energy system to meet the high-power demands of Lakeshore Die Cast required careful planning and engineering expertise. Ken Zebarah tailored the solar systems to the company's specific energy needs. The 150kW array was meticulously engineered to optimize sunlight capture and ensure maximum efficiency.
Following the success of the smaller system, Zebarah and his team designed a larger 1.5MW solar array. This system was engineered to seamlessly integrate with Lakeshore Die Cast’s existing infrastructure, providing a reliable and sustainable energy source. The in-house team managed the installation and continues to maintain the systems, ensuring ongoing peak performance and efficiency.
Quantifying Success: Energy Generation and Cost Savings
The solar arrays implemented at Lakeshore Die Cast have exceeded performance expectations. With a combined nameplate capacity of 150 kWdc and 1,493.1 kWdc, the systems were projected to generate 2,215 MWh annually. However, they outperformed these projections, producing 2,310 MWh in 2024 and 2,230 MWh in 2023.
These impressive energy generation figures translate into significant cost savings. Lakeshore Die Cast has achieved annual savings of $215,860 and is projected to save approximately $12,270,678 on utility bills over the next 25 years. This financial stability is crucial for the company’s long-term growth and operational efficiency.
Sustaining the Future: Environmental Benefits and Long-Term Impact
Beyond the financial benefits, Lakeshore Die Cast’s transition to solar energy has substantial environmental advantages. The solar arrays offset as much CO2 as burning 2.8 million pounds of coal and emitting 173 metric tons of CO2. This significant reduction in carbon emissions aligns with global efforts and promotes a cleaner, more sustainable future.
Furthermore, Lakeshore Die Cast has leveraged various incentives to make the project financially viable. The company factored in a 26% Federal Investment Tax Credit, accelerated depreciation, and secured a USDA REAP Grant (25%) for the initial 150kW system. These incentives reduced the return on investment (ROI) to just 4.5 years, making the transition to solar energy not only environmentally responsible but also economically advantageous.
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