Blueprint: Eaton’s approach in Arecibo

We recently completed clean energy projects at our Arecibo manufacturing facility in Puerto Rico where we make circuit breakers. Implementing energy efficiency measures at our plant reduced our energy use by 45%. Adding a solar-plus-storage microgrid is giving us greater control over our energy supplies and costs. Together, these measures are substantially boosting energy resilience, cutting our carbon footprint and reducing our energy spend by nearly 20%

The microgrid system, in particular, provides a powerful approach to take control of our energy supplies and reduce our carbon footprint. This system balances where, when and how electricity is consumed. It provides the control over our onsite energy sources—including the solar, storage and existing onsite generators—and enables us to island from the grid, keeping the power on, for example, even when the grid is down.

Importantly, the microgrid system is designed to withstand Category 5 strength hurricane-force winds and perform reliably and safely – even in the face of extreme weather events.

During normal operations, when connected to the grid, the microgrid provides value by generating renewable energy that can be consumed, stored and delivered to our plant or the grid—helping reduce our energy costs and reducing stress on the local infrastructure.

We collaborated with Enel North America on the microgrid system in Puerto Rico. Enel North America financed the project under an energy-as-a-service model, shifting our investment from a capital to an operational expense. We provided installation expertise and provided key technologies, including our Power Xpert microgrid solutions and leading power distribution equipment.

And we’re doubling down on microgrids to power our manufacturing in Puerto Rico. Together with Enel North America, we’re building a second microgrid at our Las Piedras facility.

Tips to strengthen the energy backbone for manufacturing

1. The best energy is the energy you don’t use. Driving efficiencies in how you use energy is key. From lighting to motors there are many opportunities to cut energy consumption.
2. Adding onsite distributed energy resources (DERs) can help reduce your electric bill and carbon footprint. At Eaton, we’ve been doing just that for years, and have deployed more than 25 renewable energy systems to help power our operations around the world.  For example, we added onsite solar PV systems at multiple facilities in Pennsylvania over a decade ago, helping reduce emissions and energy costs year over year. These projects included a factory, office building and training center. Although the energy needs for each facility are unique, the solar PV systems at each location are designed to deliver reliable, low-carbon energy well into the future.
3. Energy storage is key. It provides the means to strategically use your self-generated energy even when the sun isn’t shining. Meaning you can reduce your peak demand charges and further cut your utility bill. 
4. Microgrids provide powerful flexibility and control. When you have onsite solar, energy storage, generators and/or other DERs, microgrid control enables you to power your operations even when the grid is down. Importantly, microgrids also provide a means to add electrical capacity without changing your utility service to support increasing electric demand.
5. Flexible energy systems are vital to powering manufacturing. The steps you take today can establish the foundation to support increasing electricity demand as electrification takes off. Providing the provisions to scale your energy infrastructure, so you can add DERs as you see fit.
6. Digital technologies are helping organizations make smarter decisions. The connectivity and actionable insights afforded through digital software and hardware applications are helping boost productivity, safety and uptime in manufacturing environments. Whether keeping a closer eye on preventive maintenance requirements or modeling the ROI of potential upgrades, digitalization is the key to create a foundation for continuous improvement.
7. Work with your local utility early on in your project. Every utility has its own set of rules for interconnection, and you need to know the requirements for your system and the implications it will have on your energy spend. By engaging with your local utility early on, you can be better positioned to size your project appropriately, plan ahead for interconnection requirements and ensure you meet local requirements.   

Now is the time to develop climate-friendly power infrastructure

In a world increasingly reliant on electricity and focused on sustainability, adopting a more intelligent approach to power manufacturing is crucial. Businesses must strategize to prepare their facilities for the evolving energy landscape. In my opinion, microgrids are an important tool to meet the moment and prepare for the future. These intelligent systems offer greater control over energy systems, unlocking opportunities for increased efficiency, resilience and decarbonization while making the integration of DERs simple and straightforward. Moreover, regional or government funding and tax incentives can help turn your clean energy aspirations into reality, making the shift toward sustainable manufacturing more achievable than ever.

At Eaton, we’re dedicated to advancing resilient and sustainable energy supplies for ourselves and our customers. We believe a stronger future for the manufacturing industry is possible and we’re investing heavily in the innovation to make it happen.