The Energy Overhaul

Step One

Cardinal’s manufacturing and distribution facility in Azusa has served us well for many years. It has produced Cardinal’s own branded pet products for many years as well as serving as a contract manufacturer for many other successful companies in the pet industry.

Cardinal has won numerous awards from the Environmental Protection Agency and The County of Los Angeles for being a good citizen of the environment but our building, like many facilities, had many areas that were no longer energy efficient.

Being energy independent involves much more than simply harvesting solar energy, it also entails using energy prudently and efficiently. Before Cardinal installed a renewable energy solar collection system, we prepared to give our building a complete energy overhaul upgrading to high efficiency equipment to reduce our energy consumption to the lowest possible level.

We did a complete energy audit of our building, and replaced our power-consuming components with more energy efficient alternatives. For example, we installed Parabolic Skylights to actually “harvest” daylight, then distribute it evenly for optimal lighting efficiency. Maximum diffusion of the light collected from the skylights replaces electric lighting 70% to80% of the daylights hours.

In addition to cutting down on electric consumption, the use of prismatic light produces much less heat than electric lighting and helps reduce the temperature in the factory. This is a good example of how energy efficiency steps build on themselves.

The electric lights we used in the past have been replaced with more efficient T-5HO, High Bay Fixtures, which draw much less power than the lighting we were using, We re-wired all the light in the building from 110 to 277 volts, we also installed a software-based system that automatically controls lights in halls and offices so we are not wasting energy by illuminating areas of our building when they are not in use.

Another state-of-the art Powerlink™ Energy Management System controls the climate and monitors the complete energy system usage for optimal efficiency from a single computer. This system is hooked up to a plasma screen in our lobby, so the employees and visitors can see the electrical consumption as it happens.

All electric motors used in the manufacturing process were re-wired for 480 Volts and receive new VFDs (variable frequency drives), adding up to 30% savings of energy. Existing 600 amp 120/208 v 3-phase distribution gear and all sub panels were removed and the new 2000 amp 277/480 v Square D distribution gear was installed outside with all the new dedicated sub panels in various locations. Every tank used in manufacturing now has dedicated switches with hard-wired connections. Two new exhaust systems were strategically located in specific areas. Filtered make-up air fans remove stale air, humidity, odors and provide cooling.

Installing A Title 24 White/Cool Roof

Step Two

A roof plays a key role in reducing the amount of energy needed to heat or cool a building. In compliance with Federal Title 24 standards, we installed a foam insulating barrier on the entire roof with a very rugged, very reflective white coating over it.
This combination immediately lowered the energy demand inside the building and reduced the temperature by 15 degrees, a major step in creating a more comfortable environment for our employees. Again, the energy saving steps tend to build on each other.

Controlling the Air Quality in the Factory

Step Three

Goodman High Efficiency 13 Seer Air Conditioning units were used to replace the old units that served the office areas and three 10 Ton units were added to keep the factory comfortable and control the humidity. They utilize R-410A earth-friendly coolant. Economizers (480 v 3-phase units) were added to make sure the building had plenty of fresh air.

A unique new Fabric Duct Sock System inflates as the system turns on and distributes air throughout the large manufacturing area. The Energy Management System Monitors and maintains optimal air flow so energy is used efficiently yet the air is kept at the same constant temperature, and humidity.

Carbon dioxide sensors were installed and monitors were placed throughout the factory. Air curtains were installed above each exit door to maintain air quality and temperature and prevent unfiltered outside air from coming into the building.

The Solar Collection System

Step Four

The most noticeable feature of our energy overhaul is the solar collection system. Over three hundred Siliken Renewable Energy™ aluminum framed solar panels are installed on the roof to collect energy. These 3’ x 5’ American-made panels are arranged for maximum exposure to sunlight. They cover 5,440 square feet of space on the roof and generate 71.4 kw of AC power per hour.

The solar panels contain electronically connected photovoltaic (PV) cells that absorb sunlight in the panels. The cells knock loose electrons they absorb which allow the electrons to flow freely, forming a Direct Current (DC). This current is directed by wiring to state-of-the-art Sunny Towers Inverters which convert the power from Direct Current (DC) to an Alternating Current (AC) format that is compliant with utility company standards.

The AC power is then fed to the Cardinal building with excess power being sent directly to the utility company’s grid. In our case, the City of Azusa has its own Light & Water Company, so the power goes directly back to our city, contributing to the Federally Mandated 20% of Renewable Energy it must supply to its own customers.