energy savings

Press Release:

Lapp Insulators Co. LLC changed a decades-old process to incorporate new technology and equipment that results in energy savings, lower operating costs, and a safer work environment. The changes also earned the Le Roy-based company $27,000 in energy efficiency incentives from National Grid.

Lapp is a leading manufacturer of high-voltage insulators for electricity substations. The company recently replaced a 150-horsepower, high-pressure air compressor that had been used for 40 years with three Wilden Air diaphragm pumps to push 1.5 tons of liquid clay through its production lines. Lapp officials are pleased with the results, which include a 70 percent energy savings.

“This was a major change to our process,” said Facilities Manager Ron Richards, who worked with National Grid Energy Efficiency Specialist Jay Snyder to identify the opportunity and execute a plan to install the new pumps. 

“By collaborating with Jay and sharing ideas, we significantly improved our process, which means less downtime and more productivity. The new pumps make our employees and work environment safer, and we anticipate long-term operations cost and maintenance savings. We’re making higher quality products and are doing more with less.”

Richards said that the previous production process required approximately three times as much energy. The aqua-colored, soft, squishy clay is the main ingredient that Lapp uses to shape, fire, and glaze ceramic insulators that are used at electricity substations across North America. Around 130 people work at the Le Roy facility, which dates to 1916.

“At the foundation of our energy efficiency program is the ability to collaborate and learn from our customers so that we can better understand their needs and work together to find ways to lower their costs and reduce energy use,” said National Grid Regional Director Ken Kujawa. “When costs can be lowered and kept low for companies like Lapp Insulators, it can help them to grow, keep their facilities local, and build their workforces.”

“Our ability to work with Lapp Insulators to achieve energy efficiency goals and streamline production illustrates National Grid’s commitment to them, as well as all local manufacturers,” added Snyder. “The solution that we developed with Lapp has resulted in additional discussions about future projects to improve efficiencies and reduce costs in other areas of the facility, including lighting, an air compressor, dust collector motors, and an air dryer.”

Funding for the Lapp project was provided through National Grid’s Energy Efficiency Program, which includes financial incentives for commercial and industrial customers who reduce electricity costs. Incentives are available for customers who install energy-efficient lighting, controls, HVAC equipment, motors/electronic speed controls, and other systems that reduce energy use and/or enhance productivity.

County officials can expect a state rebate for their energy-saving efforts that began last spring.

How much of a rebate remains to be seen, Deputy Highway Superintendent Paul Osborn told the Public Service Committee on Monday.

In the update, Osborn said his department is waiting to receive summary reports from the New York State Energy Research and Development Authority to show where savings have been made and where more savings can occur later on.

“NYSERDA still has to review all of it to make sure that the realization of the energy savings that they say that they were going to do initially is realized again as well,” Osborn said. “And then, if there is more realization in the savings, then they give us a rebate for that.

“We are not anticipating a significant rebate, but we are anticipating some rebate from them. So, we can take that rebate and put it into some of those facilities that they reviewed that may need some work.”

Some cost savings will be realized with the completion of smaller projects like switching lighting in county buildings to more energy-efficient systems. More extensive projects include electrical panels, boilers, HVAC systems and breakers or air handlers.

So far, heating at County Building #1, ventilation and insulation work at the animal shelter and HVAC improvements to the highway garage have been underway.

Osborn said that once the NYSERDA report is released in late July, it will paint a clearer picture of where the funding can be allocated.

“Our biggest thing is we want to see the report — see where our idealized savings can be furthered,” Osborn said.

County Manager Jay Gsell added, “The Highway Department has one of our older buildings. [It] is also one that had probably the least internal changes made to it as with anything with HVAC and lighting and other things. So, this is one of those times, finally, let’s really make some significant improvements.”

The energy-savings projects are being conducted by Johnson Controls, which entered into a $4 million contract with the county last spring after the company conducted an energy consumption audit of county facilities in 2017.

The projected energy savings are expected to be nearly $4.3 million, for a potential net savings to the county of about $300,000.

There was debate about whether to hire Johnson Controls, but a key selling point was the claim that energy-saving projects will pay for themselves in 20 years.

Initially, legislators Gary Maha and Andrew Young approached the agreement with skepticism, while legislators Shelly Stein, Marianne Clattenburg and John Hilchey expressed their approval.

The Johnson Controls contract allows the county to undertake projects that are already part of the county's capital investment plans and save money on existing utilities. The money saved from lower energy costs will flow back into the capital project budget to cover additional upgrades.

Legislators seemed satisfied with the information contained in the energy-saving projects update and raised no objections.

Stein requested that Osborn return to the Public Service Committee in September to present the next update on Johnson Controls.

Rather than borrow $4 million with a 20-year payback to finance several energy-saving projects at county buildings, which was meeting some stiff opposition from some members of the County Legislature, a new plan for the county to loan itself the money for the contract with Johnson Controls went over well Wednesday at the Ways and Means Committee meeting.

County Highway Superintendent Tim Hens presented the proposal yesterday and was told to return at the next Ways and Means meeting with a resolution the committee can vote on.

The plan would: use $1.1 million that the county needs to spend anyway on some need capital improvement projects; use $1 million from the building equipment reserve; and borrow $1.8 million from the infrastructure fund.

The county would pay its money saved from the lower energy costs to pay back its infrastructure fund at 2-percent interest. Over the 10-life of the loan, the county would pay itself more than $200,000 in interest that would flow back into the infrastructure fund.

That's a lower interest rate than proposed for the original $4 million loan, which is 3.5 percent, and lower than the 5-percent interest County Treasurer Scott German estimated a municipal bound would cost.

Over the 20-year life of the contract with Johnson Controls, by paying off the entire cost of the contract in the first 10 years, the county will realize the benefit of an additional $800,000 in energy savings in that second 10 years. That money would have been paid toward the loan if the whole $4 million was financed by Bank of America.

Hens also discussed another proposal floated by some members of the legislature two weeks ago, that the county put down $1 million on the loan. That would also save the county money, but not as much as the self-financing option.

"I think it is a good deal for the county under all three scenarios," Hens said. "The self-funding option is by far the most beneficial to the county in terms of savings to the county and return on the investment."

Most of the opposition to the original proposal came from legislators Gary Maha and Andrew Young. Young could not attend Wednesday's meeting and Maha didn't express any objections -- nor strong support -- for the revised plan.

Marianne Clattenburg, Shelly Stein, Bob Bausch and Gordon Dibble all seemed to react favorably. Greg Torrey didn't express an opinion either way.

Legislator John Hilchey was particularly enthusiastic.

"There are very few times that a government can spend money and have it pay for itself," Hilchey said. "You can put a new road in; you can put a new bridge in; you can build a new jail. They don’t pay for themselves. This is an opportunity to make an expenditure that will pay itself back. To me it makes sense."

The Genesee County Legislature is having a hard time coming to terms with borrowing $4 million to potentially save $4 million or more on future energy bills.

Not every member of the Legislature believes the cost savings are real, or that the county should borrow that much money on an expectation of saving money years from now.

Legislators Gary Maha and Andrew Young are the most skeptical.

"I appreciate the effort," Young said. "I try to look at everything just as I would for my business. Would I do it? I would not borrow $4 million and hope I got it back over the next 20 years. I don’t know too many business people who would."

He called the idea, from a business perspective, "irrational."

Clattenburg said she looked at it a little differently.

"The rationale is like any homeowner," Clattenburg said. "You buy an energy-efficient furnace and your costs are cut in half and you take saving from the energy cost and use it to pay for your furnace. You talk about (as) if, I was a business. I talk about it as if I were a housewife and I was buying a furnace. That is how I would look at it."

In summary, the proposal involves the county signing an agreement with Johnson Controls that would entail the county borrowing $4 million. Johnson Controls would then act as a contractor for a series of projects intended to reduce energy consumption at county buildings.

Many of the projects are already part of the county's capital investment plans. Over the 20 years, the county would pay $200,000 a year on the loan but save an estimated $200,000 a year in energy costs. Johnson Controls guarantees a certain amount of costs savings realized in each of the first three years of the contract. The county could buy a sort of extended warranty for additional years to guarantee savings, though that isn't really being considered.

County Highway Superintendent Tim Hens first brought the idea to the Legislature in February and the Legislature gave him the green light to put together a resolution to approve a contract with Johnson Controls.

He's been to two committee meetings this week, Public Service on Monday and Ways and Means on Wednesday, to discuss the proposal with legislators. Neither committee has yet to approve the resolutions.

Yesterday, Ways and Means tabled the resolution pending more information on other financing options, such as using $2 million the county has available and borrowing only $2 million, perhaps from another source.

“I don’t just see it as a loser," Hens said during a 30-minute robust discussion of the proposal Wednesday. "I think it’s a good deal for the county. I wouldn’t be here for my third committee meeting pushing it so heavily if I didn’t think it was a great idea for the county.”

The benefits as laid out by Hens, County Treasurer Scott German, and the legislators who support it -- Shelly Stein, Marianne Clattenburg, John Deleo, and John Hilchey -- include:

• Front-loading paying for several capital-improvement projects that the county will have to pay for eventually anyway;
• If the contract is signed by May 30, an interest rate of 3.5 percent is locked in (the Federal Reserve is planning three interest rate hikes this year);
• Getting the work done before inflation drives up the costs;
• Shifting some of the operational expense of energy from an expense against property taxes into an expense against sales taxes, which frees up space for other expenses under the tax cap;
• Saving maintenance and repair costs on old and failing equipment;
• Ensuring employees are working in safe and comfortable buildings that currently need significant repairs

Maha said he isn't against the idea of getting the work done, but he isn't comfortable on taking on a $4 million loan with a 20-year payoff, especially when the county is looking at a potential expense of $45 million or more for a new jail.

"The timing of it bothers me," Maha said. "I understand the benefits of the energy efficiency at the county buildings but I look at my home, you know, I haven’t put any energy into my home until I have the money. I don’t think my constituents want me to say 'yeah, go ahead and borrow $4 million' when we’ve got other projects out there that will cost the county millions of dollars.”

Not every project in this proposal will, by themselves, lead to cost savings. Putting a new roof on the highway garage, for example, won't reduce energy costs but it must be done and it can be included in the contract. Making it part of the Johnson Controls contract takes it out of the list of other capital projects the county must pay for using the existing capital budget.

Most of the cost savings actually come from some of the smaller projects, such as switching lighting in county buildings to more energy-efficient systems.

Some projects, such as replacing the eight air handlers on the roof of County Building #2, will both reduce energy costs and save maintenance costs.

"Right now we spend a ton of time repairing broken air handlers in Building #2," Hens said on Wednesday. "We don’t have great job-costing software to be able to track exactly what we spend, but I can tell you, Terry and the other guys have a lot of overtime going in after hours to fix air handlers or going to the jail to repair the boiler."

Deleo admitted to some skepticism of the proposal but near the end of the discussion Wednesday, he said he had warmed to it.

"So you’re saying right now cash is cheap, so let’s lock it in at the low rate and keep that over the 20 years because it’s cheap now, and then we’ll keep our cash in reserves and if things go off, we always have the cash, and cash is king, as they say," Deleo said. "I’m not as negative against this anymore as I hear it more and more."

Young said he doesn't think the savings is sufficient enough to justify taking on $4 million in debt. Using a calculation provided by Johnson Controls called Net Present Value, Young said there are essentially no savings.

The initial NPV calculation showed only $1,357 in savings on the value of the money, but Hens said with a lower financing rate, the new calculation is $38,519.

"I’m not 100-percent confident, there’s no guarantee it’s going to pay for itself in 20 years," Young said.

Net Present Value is a term economists use to try and determine the value of money today against the value of money at some point in the future. The calculations can get complicated. A straight calculation of $4 million today versus the value of that money in 20 years would, at a steady rate of 2-percent annual inflation, be $2.7 million.

Such straight-line calculations through having little predictive value. We don't know what the rate of inflation will be in each year, what interest rates might be in future years (if money isn't borrowed now and is instead borrowed on a project-by-project basis in coming years); and in this case, how the cost of energy will change over 20 years.

Maha is concerned about placing bets on the prediction of the future, he said. Who knows what technology changes will come in 20 years? He suggested in 20 years, whoever is still around in county government will have no real knowledge of why the loan exists and what purpose it served.

"I want to reiterate that my concern is, I don't care if it's $1 million or $4 million, I don't like the 20 years," Maha said. "Who knows what is going to happen 20 years down the road. Who is going to look back in 20 years and remember why we did this?"

Clattenburg countered, “We might look back in 20 years and say look at all the money we saved over the 20 years.”

Both Hens and German made the point a couple of times during the discussion that the estimated saving presented by Johnson Controls should be considered "conservative" estimates that the actual cost savings should be higher. Johnson Controls, Hens noted, with the first-three-year guarantee on its estimates, doesn't want to overestimate and wind up owing the county money, so their estimates are cautious.

Clattenburg, who chairs Ways and Means, was perhaps the staunchest proponent of the Johnson Controls proposal.

“If we don’t do this and we go the other route (paying for each project individually), don’t come to me to override the tax cap at any point," Clattenburg said. "I hope you are willing to do that if we don’t go this way because that’s what’s going to happen."

Neither legislators Bob Bausch nor Gregg Torrey expressed an overt opinion on whether they will support the proposed contract. But Bausch suggested that maybe the county could use current capital project funds along with some reserves, up to about $2 million, to reduce the amount of money borrowed. That would both reduce the total amount of interest paid and reduce the length of the loan, perhaps to as little as six years.

Hens said that would mean going to another firm for financing and losing the guaranteed 3.5 percent rate. German said he would have to gather estimates but the rate wouldn't be guaranteed until the county was actually ready to take out the loan, which could be two months.

The committee agreed to table the resolution until German is able to report back on that option.

CLARIFICATIONS: We should have pointed out in the body of the story that the estimated cost savings on utility bills alone if the loan is taken out is $117,250. Hens says that's a conservative estimate based on an inflation rate of 3 percent over 20 years. He said the actual rate since 1998 has been 3.9 percent and going back to 1958, the averaged annual rate of inflation for energy costs has been 4.32 percent. If either of those figures hold true, he said, the county will save substantially more.