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Case Study:TechJet
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Background |
TechJet Aerofoils Ltd., a world leader in the development and manufacturing of compressor blades, is a joint venture owned by Rolls-Royce Plc., the Wertheimer Group, and BTL Ltd. Based in Tefen Industrial Park in northern Israel, the company manufactures up to 500,000 aerospace compressor blades per year. The company was founded in 1999, with a major goal to significantly reduce end-user prices and manufacturing costs for aerospace blades, while maintaining top quality, precision, on time delivery, and full production floor automation.
In December 2002, TechJet Aerofoils Ltd. was awarded a certificate of excellence for environmental achievement, for projects including a unique facility for wastewater treatment that resulted in zero discharges to the sewage system. The company has also stopped lead plating, initiated professional treatment of hazardous materials, and reduced waste quantities at the source.
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Original Situation |
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TechJet’s lighting system consisted of fewer than 100 lamps using 400W magnetic ballasts. Metrolight proposed setting up a pilot site for TechJet, using Smart Electronic Ballasts for HID™ to compare consumption figures and provide real energy savings. Should the results prove significant, TechJet would then retrofit their entire factory using the Smart Electronic Ballasts for HID™.
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The Solution |
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The first pilot was installed in 2005, and included tens of units of 320W Metrolight Smart Electronic Ballasts for HID™ and 320W lamp preset to 260 Watts.
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The Result |
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After running the pilot and carefully measuring energy consumption, TechJet gained energy savings of 43% without compromising light output, despite using lower wattage lamps and preset dimming. TechJet is now deploying the Metrolight system throughout the entire factory. In addition, TechJet installed the Metrolight Diagnostic™ software for monitoring and control.
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| Features |
Before Installation |
After Installation |
| Lamp Power Wattage / Setup |
400 Watts |
260 Watts |
| Power Consumption W |
485 |
277 |
| Lumens Measured |
300 Lumens |
450 Lumens |
| Operating Hours |
24 |
24 |
| Electricity Cost $ |
0.10 |
0.10 |
| Total Installation Cost $ |
- |
$18,600 |
| Total Annual Electricity Cost $ (US$) |
$24,393 |
$13,911 |
| Average Annual Maintenance Cost1 (US$) |
$1,296 |
$600 |
| Total Annual Savings $ |
$11,178 |
| ROI |
1.66 |
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Notes:
1. Relamping every 2 years with magnetic ballast and 5 years with Metrolight Smart Electronic Ballast for HID™
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