ONSITE says California aerospace plant cut energy use 10% and saved over $200,000 a year

ONSITE Utility Services said a California aerospace manufacturer cut annual electricity use by more than 10% and saved over $200,000 a year after a facility-wide LED and power-quality upgrade. The project was completed with no upfront capital from the manufacturer and preserved $650,000 for production expansion.

Why it matters: - ONSITE Utility Services said the project lowered energy costs without forcing the manufacturer to spend capital upfront. - The upgrade also cut carbon emissions by more than 1,000 metric tons a year. - The manufacturer kept $650,000 in capital for expansion instead of tying it up in energy equipment.

What happened: - ONSITE Utility Services announced results from an energy-efficiency project completed for a large aerospace manufacturer in California. - The project combined a plantwide lighting retrofit with power-quality upgrades. - The manufacturer reduced annual electricity use by more than 10% after the work was completed. - Annual electricity costs fell from $2,148,706 to $1,928,463. - Annual electricity consumption dropped from 13,944,534 kWh to 12,515,219 kWh.

The details: - ONSITE reviewed 12 months of utility bills and the facility's mechanical equipment inventory before performing an onsite audit. - The company replaced aging T8 fluorescent fixtures with high-efficiency LED lighting across the plant and office space. - The lighting upgrade improved illumination on the factory floor. - ONSITE also installed power optimization equipment at all three switchgear locations feeding the facility. - The power system work balanced voltage across all three phases. - The equipment captured transient voltage typically lost to ground. - The project reduced KVAR, the reactive power customers pay for but cannot use. - The plant reported fewer maintenance issues after the upgrade. - The manufacturer also reported higher overall production. - The entire project was delivered through ONSITE's Energy Savings-as-a-Service platform. - ONSITE provided 100% of the capital under a 60-month service term. - The structure avoided $650,000 in upfront capital expense. - The customer retained $4,160 in monthly savings at zero capital cost. - ONSITE said the project generated over $200,000 in yearly savings and eliminated more than 1,000 metric tons of CO2.

Between the lines: - The project shows how energy upgrades can compete with internal capital priorities when budgets are tight. - The financing structure matters as much as the equipment in this kind of deal. - For industrial operators, power quality can affect both maintenance costs and production, not just utility bills. - ONSITE framed the result as a way to cut emissions while preserving cash for growth.

What's next: - The manufacturer plans to use the preserved capital to expand production lines. - ONSITE continues to offer Energy-as-a-Service projects for commercial, industrial, healthcare and municipal facilities nationwide. - The company says customers keep 100% of ongoing savings after the service term ends.

The bottom line: - The aerospace plant got lower bills, fewer maintenance issues and a smaller carbon footprint without paying upfront for the upgrade.