Saint-Gobain, Huntsville Plant: Energy-as-a-Service

The Challenge

Saint-Gobain is the world’s largest building materials company.  They currently operate 265 locations within North America and have been recognized as a top employer for an exceptional workplace and employee benefits.  Saint-Gobain’s Huntsville plant is a large manufacturing complex, where materials are crushed and heated to make high-performance abrasives. The facility is currently illuminated by a mix of outdated metal halide and fluorescent lighting — both of which pose a number of health and safety risks. Driven by a strong commitment to improving both productivity and sustainability, Saint-Gobain was looking for a lighting solution that would provide safer, more energy-efficient lighting, while reducing energy usage and costs.

The Solution

SmartWatt engineers worked closely with Saint-Gobain to design a lighting solution that aligns perfectly with the specific needs of the facility and plant employees. Replacing the energy-draining metal halide and fluorescent lights with high-efficiency LEDs — using dust-tight, heat-resistant, and wash-down rated fixtures as needed, ensures long-term savings and functionality and improves working environments and productivity.

Furthermore, we recommended that the plant take advantage of our Energy-as-a-Service platform in order to avoid all capital expenditures/maintain a positive cash flow, and reduce maintenance and operating expenses.  Real-time energy monitoring devises will track energy usage throughout the plant, increasing business intelligence and efficiency.

The Impact

Annual energy consumption will drop from 2,502,775 kWh to just 628,500 kWh, resulting in annual energy cost savings of $116,200, and annual maintenance cost savings of $24,000.

In addition to the cost savings, Saint-Gobain’s upgraded lighting system will have a positive impact on the environment by removing 2,845,000 pounds of carbon dioxide, 4,741,800 grams of sulfur dioxide, and 11,000,000 grams of nitrogen oxides

Removing those pollutants from the air equates to planting 417 trees and removing 269 cars from the road each year.

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