Retrofit Success Stories
DISCOVER HOW BUSINESSES ARE BENEFITTING FROM RETROFIT:

 

 

ARCELORMITTAL TAILORED BLANKS

Arcelormittal Success Story

"This program is very flexible. It's not just about lighting upgrades."
Michael Lue
Engineering Manager ArcelorMittal Tailored Blanks

Laser welding is ArcelorMittal Tailored Blanks core business. However, the same laser welding equipment the Concord-based manufacturer used to help automotive companies stay competitive was digging into operating costs. That's when plant engineers decided it was time to upgrade. "The RETROFIT program allowed us to move our business to a whole new level by making our laser welding process more energy-efficient," says Engineering Manager, Michael Lue. "This program is very flexible. It's not just about lighting upgrades."

THINKING SMART
At its 120,000-square-foot facility north of Toronto, ArcelorMittal Tailored Blanks has earned a global reputation for using state-of-the-art laser welding technology to produce 4,000,000 tailored welded parts, including B-pillars, rails and door inners, every year for automotive powerhouses such as GM, Ford and Chrysler. But powering the technology isn't cheap.

"Lasers use a lot of energy," says Lue. "Three years ago, we were using CO2 lasers, which are real energy guzzlers. We decided it was time to start looking at different options."

TAKING ACTION
Lue discovered there were several ways to take advantage of the RETROFIT program. "Many people use it to help finance lighting and compressed air system upgrades. But we wanted to install new laser equipment and so we worked with our account executive at Alectra Utilities (formerly PowerStream) to develop a custom application. The first project we did was in 2012. We replaced one of our lasers and related chilling equipment. Then in 2014, we replaced another one, as well as upgrading our lighting and compressed air system. We still have one more laser to replace, so we will be making another custom application shortly."

GETTING RESULTS
By thinking outside-the-box, Lue is helping ArcelorMittal Tailored Blanks to save approximately $280,000 annually in electricity costs. "For the first two laser replacements, we were really pleased to receive incentives of roughly $173,400, based on combined project costs of $865,600. We also did some lighting and compressed air upgrades. The incentives we received through the RETROFIT program really help."

SAVINGS
Project Cost
$1,030,000
Less: Incentive
$262,429

NET COST
$767,571
Energy Savings
2,213,294 kWh
Demand Savings
356.7 kW
Estimated Annual Electricity Savings
$243,462

Estimated Payback
3.2 Years


APPLY FOR RETROFIT TODAY!


MIKE AND MIKE'S ORGANICS INC.

Mike & Mike's Organics Success Story

"With the incentive we received, our up-front investment will have paid for itself in 3 years."
Robert Kuenzlen
EVP Mike and Mike's Organics Inc.

In 2014, Mike and Mike's Organics Inc. had big plans - plans to double the size of their certified organic food distribution facility, while minimizing the increase in their electricity costs. All the while, complementing the company's sustainability goals.

TAKING ACTION
Mike and Mike's Organics had worked with Rosetown Central Refrigeration & Air Conditioning Ltd. before and sought their help again. Dan Whitten, General Manager, recommended a custom refrigeration system with 12 compressors. When needed, the compressors turn on one by one to match the cooling capacity required. The electronic controls work to monitor the cooling so only the energy required is used, unlike conventional systems that are all on or all off. LED lights were also installed inside the fridges to further reduce energy consumption.

THINKING SMART
Forklifts buzz in and out of the four 20-foot-tall fridges at Mike & Mike's Organics. Throughout the brightly-lit 43,000-square-foot facility in Woodbridge, Ontario, employees prepare an average of 100 shipments a per day to independent health and natural food grocers across the Greater Toronto Area. Due to the fact that organic food contains no preservatives, the fridges require precise cooling systems in order to maintain optimum freshness. The lights and chillers operate 12 hours a day, six days a week, meaning a constant draw of electricity. The fridges maintain this temperature 24/7/365 days a year. "When we started thinking about adding to our existing floor space in this complex, our top priority was ensuring our electricity costs didn't go through the roof as a result of the expansion," said Kuenzlen.

GETTING RESULTS
With support from Alectra Utilities (formerly PowerStream), Mike and Mike's Organics submitted an application to the RETROFIT program. "We invested $56,000 for project costs and received an incentive payment from Alectra Utilities for about $13,000. The best part is we'll be able to manage our ongoing electricity costs well after the equipment payback period. It's a wise investment."

SAVINGS
Project Cost
$56,000
Less: Incentive
$12,925

NET COST
$43,075
Energy Savings
129,250 kWh
Demand Savings
2.6 kW
Estimated Annual Electricity Savings
$14,218

Estimated Payback
3 Years


APPLY FOR RETROFIT TODAY!


GIBSON BUILDING SUPPLIES

Gibson Building Supplies Success Story

"I had expected the incentive might amount to 20 or 30% of our capital cost. I was delighted when it turned out to be 50%."
Lee Whitwell
Controller Gibson Building Supplies

Gibson got the sticker shock of a lifetime when the company moved into a new warehouse location in 2012. "The warehouse had been wired to keep the lights on all day long, and as a result, our first electricity bill was almost $10,000," says Controller Lee Whitwell. "That was the reality check we needed to start reining in our electricity costs. We looked into the RETROFIT PROGRAM, did the math and never looked back."

A BRIGHT DECISION
Gibson Building Supplies provides roofing materials and supplies to residential, industrial and commercial roofing contractors across south-central Ontario. A family-owned business, it was established in 1972 and operates primarily from a central 100,000 square-foot warehouse in Aurora, as well as satellite facilities in Milton and east GTA.

It made more sense for Gibson Building Supplies to upgrade to T8 lights and install overhead motion sensors than to rewire the entire warehouse. Motion sensors mean that today the warehouse is constantly lit when forklift drivers need to load and unload materials, and when activity stops, the lights automatically shut off. "I had expected the incentive might amount to 20 or 30% of our capital cost. I was delighted when it turned out to be 50%. This program is a no-brainer," says Whitwell.

GETTING RESULTS
"Ampower was a pleasure to work with. They worked around our needs and were completely flexible. Within a month, we had the green light from Alectra Utilities (formerly PowerStream) on the pre- and post-inspections that are part of the application process, and we were good to go. It was time to reap the benefits of our investment," says Whitwell.

TAKING ACTION
An employee of Gibson recommended Ampower Electrical Contractors to oversee the lighting retrofit and manage the application process for the RETROFIT PROGRAM. Ampower installed energy-efficient T8 lighting in the office and warehouse space and 180 occupancy sensors in the warehouse area, allowing Gibson to save approximately $5,000 on its monthly electricity bill.

SAVINGS
Project Cost
$99,500
Less: Incentive
$48,069

NET COST
$51,431
Energy Savings
342,971 kWh
Demand Savings
83.66 kW
Estimated Annual Electricity Savings
$60,000

Estimated Payback
Less than 1 year


APPLY FOR RETROFIT TODAY!


IDEXX REFERENCE LABS

Idexx Success Story

"The RETROFIT PROGRAM was the right program, at the right time."
Craig Smith
Environmental, Health, & Safety/Facilities Coordinator IDEXX Reference Laboratories

For technicians at IDEXX Reference Laboratories, good lighting is critical. That's why, when Environmental, Health, & Safety/Facilities Coordinator, Craig Smith, discovered he could reduce his improve the quality of light, reduce energy costs, and receive an incentive through the RETROFIT PROGRAM, he jumped at the opportunity.

A BRIGHT DECISION
IDEXX Laboratories, Inc. is the global market leader in diagnostics and information technology solutions for animal health, providing more than 50,000 veterinary practices worldwide with an integrated portfolio of pet-side diagnostic tests, point-of-care instruments, reference laboratory services, digital radiography and practice management solutions.

Lighting is one of IDEXX Laboratories biggest energy costs, and given the number of lights at its 33,000-square-foot Markham location, labour costs increase when lights need to be replaced. In addition to constantly looking for savings opportunities, the company also closely monitors its carbon footprint as sustainability is a core value for IDEXX globally. According to Smith, for all these reasons, the RETROFIT PROGRAM was the right program, at the right time.

TAKING ACTION
Working with Sesco Lighting, IDEXX removed over 1,200 T12 tubes, par 38's and exterior wallpacks, replacing them with high-efficiency LED lighting strips. IDEXX also installed wall-mounted occupancy sensors in several storage rooms and all washrooms. As a result, the company was approved for an incentive payment through the RETROFIT PROGRAM.

GETTING RESULTS
"Our contractor (Falstaff Electric) was terrific. The work was completed in two phases to minimize disruption," said Smith. "Alectra Utilities (formerly PowerStream) provided pre- and post-inspections, and once work got started, there were no issues whatsoever."

"We were using a lot of T12 fixtures, which are dull, and give off heat, which increases cooling demands. Manufacturers are gradually phasing them out. It was definitely time to upgrade."

SAVINGS
Project Cost
$49,599
Less: Incentive
$19,486

NET COST
$30,113
Energy Savings
344,029 kWh
Demand Savings
47.36 kW
Estimated Annual Electricity Savings
$35,800

Estimated Payback
Less than 1 year


APPLY FOR RETROFIT TODAY!


JEMS COATING LTD.

Jems Coating Success Story

"Our up-front investment is already paying off."
Robert German
General Manager JEMS Coating Ltd.

For technicians at IDEXX Reference Laboratories, good lighting is critical. That's why, when Environmental, Health, & Safety/Facilities Coordinator, Craig Smith, discovered he could reduce his improve the quality of light, reduce energy costs, and receive an incentive through the RETROFIT PROGRAM, he jumped at the opportunity.

A BRIGHT DECISION
JEMS Coating Ltd. provides epoxy-based electrodeposited coating (E-coating) for automotive parts as well as components that are used in the electrical, home building, recreational and commercial manufacturing industries, pumping out approximately 300,000 units per day at its plant in Concord, which is home to roughly 250 employees. Cost and light quality were the two reasons why German decided to invest in energy-efficient T5 and T8 lights, rather than replacing existing metal halide lights with more of the same. "With T5s, there is less regression in the bulbs luminescence over time, more light with the same current draw, and in the long-run, they're cheaper to use."

TAKING ACTION
Working with Technocrates Inc. - a member of the Alectra Utilities (formerly PowerStream) Contractor Directory - JEMS Coating installed 128 high-bay, overhead motion sensors, close to 100 T5 light fixtures, 20 T8 fixtures and retrofitted Exit signs with 5-watt bulbs throughout the plant. As a result, the company was approved for an incentive payment of over half the project costs through the RETROFIT PROGRAM.

GETTING RESULTS
"We decided to do the lighting retrofit work on weekends, over the course of about a year, to minimize disruptions," says German. "Alectra Utilities provided pre- and post- inspections, Technocrates made the implementation easy and flawless, and so far, our up-front investment is paying off."

"When I heard about the RETROFIT PROGRAM, I decided it was time to upgrade."

SAVINGS
Project Cost
$40,547
Less: Incentive
$22,295

NET COST
$18,252
Energy Savings
221,002 kWh
Demand Savings
44.02 kW
Estimated Annual Electricity Savings
$36,000

Estimated Payback
Less than 1 year


APPLY FOR RETROFIT TODAY!

 


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