Melfred Borzall (MB) has been manufacturing underground construction tools in California since 1946. Its main manufacturing facility is located on California’s Central Coast, in Santa Maria, where the abundant sunshine and mild temperatures are ideal for solar power generation. When California experienced an energy crisis in 2003, causing rolling blackouts and skyrocketing prices, MB President Dick Melsheimer decided it was time for the company to establish energy independence through solar power.

In 2004, Mr Melsheimer had 648 photovoltaic (PV) panels installed on the roof of the Santa Maria plant, producing over 77 kilowatts (kW) of power. At that time, the system produced about two-thirds of the plant’s electricity requirements.

“We were extremely pleased with the results of the initial installation,” Mr Melsheimer says. “We were now producing the majority of our electricity from the sun, a non-polluting source that does not rely on foreign oil.”

Mr Melsheimer went on to explain that PV panels produce energy when the photons in sunlight strike the silicon based panels. The electricity produced by the panels is direct current, or DC. The connected panels combine the electricity and feed it into an inverter. The inverter converts the DC power into AC, or alternating current, and matches it to the power conditions of the local electrical grid. Solar electricity combines with the grid-supplied energy, and when demand is greater than solar production, grid power makes up the difference. When solar electric production exceeds demand, the electricity is “pushed upstream” and the electric meter runs backwards. Solar power uniquely matches the fluctuations of electricity demand. Electrical demand and rates are highest during summer daytime hours. This is exactly when solar produces the most electricity. It smooths out demand peaks and helps reduce the need for additional, typically fossil fuel power plants.

By 2006, the company added more tool production equipment, increasing its electrical needs. Around this time, management installed over 450 new, larger solar panels to the existing system. The upgrade was completed in January 2007, and brought the total solar electric production to 135 kW, making it the largest system in Santa Barbara County.

“We are very excited about the upgrade to our system. The new system is even more efficient and we anticipate meeting over 90 per cent of our power requirements through solar,” says Mr Melsheimer.

September 2007 marked a milestone for MB solar power with the accumulated production of 500,000 kW hours of solar electricity; enough energy to power 30 homes for a year and reduce the production of 620,000 pounds of greenhouse gases that a fossil fuel power plant would have produced. The plant has not used any net grid supplied power since February 2007.

Melfred Borzall doesn’t stop at solar power. Recently, the company replaced the metal halide plant lighting with high efficiency T5 fluorescent lights. This reduced electrical use for lighting by half. Skylights provide free natural lighting in offices and production spaces. MB also provides flexible scheduling to employees who leave their cars at home and use public transportation. Several MB employees now regularly commute by bicycle to work.

“We try, by example and incentives, to encourage our employees to look at the ways they use energy,” Mr Melsheimer says.

In addition to solar power and energy efficiency, Melfred Borzall has a commitment to ‘doing business the right way’.

“As an independent, family-run business, we have the opportunity to choose to do business in a responsible manner. Our employees are essential partners in the business and it shows in their commitment to make quality tools,” says Mr Melsheimer.

Mr Melsheimer says contractors can feel good about the tools they purchase. “We know how hard utility contractors work. When they buy a Melfred Borzall tool, we want them to know not only is this a quality tool priced for value, but that a company who cares about how the tool was made. We have motivated, trained employees and partners making the best possible tools in clean, high-tech facilities.”