Real world experience,
with receipts.
Explore our recent case studies below.
Measurable savings in the Motor City
Drastically improves environment for major test equipment manufacturer.
Upgraded their lighting to LED, improving quality / Light levels and impacting sustainability. Link Engineering is the world’s leading manufacturer of Automotive / Aircraft / Truck / Train braking system test equipment as well as performing critical vehicle tests for their customers worldwide. This project generated $59,000 in annual savings, reduced C02 by 170 metric tons and reduced the lighting load by 66% for a total of 414,000 kWh reduced. For a deeper dive on this project please download the PDF below.
Beneath the city
MAG Energy is working seventy feet below the city of Detroit.
Partnering with Detroit Thermal, we provide reliable and efficient steam service for the many customers they serve with district energy. District steam is used to heat and air condition buildings, sanitize medical devices, assist with cancer research, and in automotive processes and several other industries throughout the city. Detroit Thermal has over 4 miles of underground steam tunnels and 25 miles of buried steam pipe as part of their distribution system.
Our skilled professionals help to provide waterproof insulation upgrades, and system leak repairs to reduce line losses and improve safety. These essential improvements ultimately reduce operating costs.
We are proud to collaborate with Detroit Thermal on maintaining this critical infrastructure. For a deeper dive on this project please download the PDF below.
Compressed Air
Master Control system install results in higher than estimated savings for General Aluminum.
Our assessment identified $118k/yr in energy cost savings through the implementation of a master control system, lowering system pressure, and properly sharing system load between two existing VSD compressors. After one week in automation, we’ve shown monthly savings of over $10k/month ($120k+/yr), exceeding our savings projections. We have also added temperature, pressure, flow, and pressure dew point instrumentation for continuous system KPI trending. As a part of the solution a pressure control valve was installed and is holding plant pressure at a steady 100 psig which keeps plant production more consistent and reliable. For a deeper dive on this project please download the PDF below.
Strategic Lighting Upgrade
Drastically improved environment for major component manufacturer.
PARK OHIO’S FRS DIVISION IN OCALA, FL faced challenges stemming from aging infrastructure and outdated lighting systems. In pursuit of comprehensive improvements, we addressed significant hurdles, notably the deteriorated bus bar system. Opting for extensive repairs over replacement proved to be a strategic decision, resulting in substantial savings of 230 kW and 1,580,000 kWh. This innovative approach was instrumental in achieving over $200,000 in annual savings and a remarkable environmental impact - 1,120 metric tonnes of CO2 offset annually. Approximately 2,000 new fixtures revitalized spaces, encompassing redesigned offices, manufacturing, and warehousing areas. The strategic use of specialty fixtures addressed unique challenges, such as high temperatures, process steam and gases, and heavy vibrations from machinery. The project not only enhanced the working environment for employees but also set a precedent for cost-effective, sustainable solutions. For a deeper dive on this project please download the PDF below.
Making the Bottling of Your Favorite Beverages Brighter
If there’s any doubt that a major LED retrofit project could benefit your enterprise, this is the video to watch. Better lighting delivers lower instances of accidents, increased worker morale, and measurable increases in productivity and quality. And of course, significantly lower energy costs. All of it adding up to surprising net-positive outcomes. For a deeper dive on this project please download the PDF below.
Megawatt
3 MWdc ballasted rooftop installation in Baltimore
MAG ENERGY completed the installation for a Global Spice Company at their largest distribution center just outside of Baltimore, MD.
Using some of the most efficient modules available, we installed 6,528, 450-watt, 20% efficient solar modules. The site is a 41-acre (2 million sq ft) building and generates 2.9 megawatts of direct current power (MWdc). 6,528 solar modules tie to 32x 62 kilowatt alternating current (kW) inverters for two megawatts of alternating current (MWac). This system will have enough power to cover this distribution center’s needs.
The second phase installation will directly connect to the grid and help provide power to the facility’s neighbors through a community solar initiative. The electricity produced in phase two could be enough clean solar energy to power roughly 5,200 homes. For a deeper dive on this project please download the PDF below.
Harsh Environments
A sweet spot for MAG Energy.
GENERAL ALUMINUM IN HUNTINGTON, INDIANA presented diverse challenges across the foundry, machine shop, warehouse, and administrative areas. This prompted a comprehensive lighting overhaul. Harsh environments created by furnaces and other heavy processes demanded specialized fixtures that could withstand the elements of the foundry. Other areas received a tailored blend of LED high bays and linear fixtures with numerous spaces being redesigned for light levels tailored to each space’s unique demands. Occupancy sensors were employed in numerous areas to capture additional savings. The exterior lighting was completely replaced. Excess cash flow from energy savings was used to fund a number of electrical upgrades. This holistic approach resulted in substantial cost savings of $46,800, reduced power demand by 46 kW, saved 592,000 kWh, and contributed to annual carbon savings of 252 metric tonnes of CO2. For a deeper dive on this project please download the PDF below.
Next Generation in Efficiency
MAG ENERGY RECENTLY COMPLETED AN LED LIGHTING UPGRADE OF CHEMTREND’S HOWELL, MI manufacturing facility. ChemTrend, a division of the global Freundeberg family of companies, is a world leader in the development and manufacturing of release agents, purging compounds, and other process chemical specialties. Freudenberg corporation has also taken a leadership role in promoting their sustainability goals across the entire global organization.
The Howell facility had undergone a previous high efficiency T8 fluorescent lighting retrofit. Although relatively energy efficient and well maintained, the system had reached the end of its useful life. Electronic ballasts were failing, fixtures surfaces were becoming depreciated and light levels had deteriorated.
The scope of work involved replacing all the existing fixtures fluorescent fixtures in the facility with new LED luminaires. Working with ChemTrend stakeholders, MAG Energy specified IP66, enclosed and gasketed vaportight models through the entire production space. This will ensure the LED engines are protected from exposure to the manufacturing process which could cause premature failure or degradation. They will also present a uniform form factor across the entire factory floor and provide a much easier-to-clean surface for ongoing maintenance. Energy savings in excess of 30% were realized, despite the efficiency of the existing system and the need to significantly increase light levels.
For a deeper dive on this project please download the PDF below.
BEFORE
AFTER
OUR VALUED CUSTOMERS
“If a project feels impossible, it’s probably the perfect project for us.”
— Greg Summerlee - VP of Energy Services