When Zytron Control Products, Inc., a manufacturer of temperature and process control equipment, learned their lighting ballasts were no longer available they were faced a dilemma—one that in both the short and long term turned out to produce significant cost and tax saving for them.
As a result of the ballast shortage, Zytron had to bring in temporary lighting in order for them to operate in certain areas. When Karen Evanko, Zytron’s field agent, learned about its lighting challenge, she recommended an energy audit to John Wilkinson, the company’s president. Rather than simply replacing the old fixtures with new ones, the audit would help improve the company’s overall energy effectiveness. Wilkinson agreed with Evanko, this would be a great idea.
NJMEP’s resource did a walk through to observe existing equipment and the building operation. It reviewed energy usage, installed equipment, operational practices, present and future facility design requirements, power interruption and recovery issues, cost per sq. ft. of gas and/or electric where applicable, third party alternative energy supplier availability and costs, and other relevant areas. Zytron provided energy usage and billing histories for past energy use and made relevant personnel, and information available for the past energy review.
Upon completion of the inspection, Zytron received a report that identified and described areas where energy can be used more effectively and how to do so. It also included estimated costs, energy and operational savings along with the rebate dollars (State and Federal) available.
The summary report provided a detailed Lighting Replacement/Retrofit Proposal showing a payback of 2 years or less.
The report proved very helpful. Zytron did a complete changeover of its lighting. Its new fixtures have two fluorescent tubes instead of the four in its old ones, which cuts tube replacement costs in half. The life expectancy of the new tubes and ballasts are almost double what the old ones were, again greatly reducing the cost. In all the new lighting, which is more energy efficient, produces more light with less tubes at a lower cost. An added benefit is the The Tax Relief Act of 2010 includes 100 percent bonus depreciation for qualified investments made after Sept 8, 2010 and before Jan 1, 2012 of which the lighting changeover qualified.
“Estimating our energy cost savings was a bit of a challenge as, in addition to the changeover of all our fixtures, we also changed our utility company that offers lower rates,” reported Wilkinson. “In spite of that complication, I was able to calculate a cost saving of 10-12% for the lighting alone. We also received a $1300 rebate from the State, which helped,” he pointed out. “And, without NJMEPs help we would not have been as successful in this endeavor as we were, he added.
Zytron Control Products, Inc. and NJMEP continue to work together— a marketing project is in the works.
Zytron Control Products is a participant in NJMEP’s Made in New Jersey program. Click here to view their profile!