October 2008 Vol. 63 No. 10
Newsline
Melfred Borzall’s Red Tools Going Green
For over 60 years, Melfred Borzall’s directional drilling and horizontal earth boring tools have been identified by their signature red color. Now, those red tools are turning green.
Melfred Borzall has been manufacturing underground construction tools in California since 1946. Their main manufacturing facility is located on California’s Central Coast at 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.
After attending an informational Pacific Gas Electric workshop to learn how to improve his company’s energy efficiency, Melsheimer realized that solar power could be a smart business move and thoughtful environmental step. In 2004, Melsheimer had 648 photovoltaic panels installed on the roof of the Santa Maria plant, producing over 77 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,” Melsheimer said. “We were now producing the majority of our electricity from the sun, a non polluting source that does not rely on foreign oil.”
Melsheimer explained that photovoltaic 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, Melsheimer said. “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.”
Upgrade
By 2006, Melfred Borzall 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 135kW, 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 percent of our power requirements through solar energy,” Melsheimer said.
According to Melsheimer, as of October 2007, the plant has not used any net grid supplied power since February 2007. Sept. 1, 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 green house gases that a fossil fuel power plant would have produced.
Melfred Borzall doesn’t stop at solar power. Recently, they 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,” Melsheimer said.
Right stuff
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,” Melsheimer stressed. “Our employees are essential partners in the business and it shows in their commitment to make quality tools.”
Melsheimer went on to say, “We try to make sure our suppliers are also concerned about their impact on the environment. We don’t import parts, castings or materials from outside the United States as some other tooling companies have started to do. Not only are there quality and safety concerns, often the materials are made in factories that pollute the environment. All MB tools are manufactured in California, using steel from American mills and castings from American foundries. Since 1999, we have purchased only U.S. made CNC machine tools and welding equipment. Our major partners, DCD, Geological Boring and Premier Drill Pipe all produce their products in North America.”
Melsheimer said 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 it makes that tool made it. We have motivated, trained employees and partners making the best possible tools in clean, high tech facilities. Our customers can tell the difference.”
FOR MORE INFO:
Melfred Borzall, (800) 558-7500, www.melfredborzall.com
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