Skip to content
Consumers Energy Trade Ally · Davisburg, Michigan

FAQ

Straight answers before you book a review

These questions come from the conversations plant managers already have with EDE. Answers match what we publish — not a generic savings range.

Audits

Facility energy audits

How do I know if our plant would benefit from an energy audit?

If you have not had a serious audit in the past five years, or if lighting, HVAC, motors, or compressed air have not been measured recently, yes. Utility rebates often make the first projects pay back quickly. Some measures pay for themselves in about a year.

Why bring in an outside survey instead of walking it ourselves?

A plant walk finds the obvious. A measured survey finds idle loads, simultaneous heating and cooling, leak cost, and controls that never got programmed. EDE ranks that work so operations and finance can act on the same list.

Lighting

LED and network lighting controls

What is network lighting control?

Sensors and software adjust lighting for occupancy, daylight, required light levels, and schedules. That typically cuts lighting energy 30–40% beyond LED-only operation and can roughly double fixture life because fixtures run cooler and fewer hours.

Can we add controls to LED fixtures we already installed?

Yes, when drivers support 0–10V dimming or an auxiliary input. This is now one of the fastest ways for LED-only buildings to capture more savings. EDE is doing these retrofits today.

What is the difference between a traditional lighting system and one with NLC?

Traditional lighting runs on fixed schedules or breakers, often at 100% whether the bay is occupied or not. Network lighting controls use sensors, software, and gateways so output follows occupancy and daylight. That typically adds 30–40% lighting energy savings, can increase rebate value, and supports scheduling, emergency-fixture checks, and energy reports.

How does LED with network lighting controls save money versus LED-only?

A 150 W LED fixture that stays at 150 W all shift wastes light whenever the floor is empty. With controls it can drop to about half output when occupancy is partial and much lower when the area is empty. Heat maps in the software show occupancy so settings can be tightened as data arrives.

Why do lumens per watt matter when we buy LED fixtures?

Lumens per watt (LPW) is how much light a fixture delivers per watt. Many supply-house fixtures land at 140–150 LPW. For the past six years EDE has specified a 200-LPW fixture and has not seen field failures attributed to that choice. Higher LPW lets a lower-wattage fixture deliver similar light: a 150 W fixture at 140 LPW yields about 21,000 lumens; a 100 W fixture at 200 LPW yields about 20,000 lumens and uses 50 W less per hour.

Compressed air

Compressed-air leak work

What does a compressed-air leak audit include?

EDE uses ultrasonic leak detection, tags and photographs leaks, estimates cost, and often logs the compressor plant for up to two weeks. Listening walks and soapy water miss most leaks.

What kinds of leak detection exist?

Plants still use auditory walks and soapy water. Those methods miss a large share of leaks. Ultrasonic detection is the professional method EDE uses because it finds leaks that cannot be heard over production noise.

HVAC and electrical

HVAC, power quality, and monitoring

Where does HVAC waste usually hide?

Poor scheduling, oversized equipment, missing controls, simultaneous heating and cooling, and ventilation that does not match occupancy or process load.

What is power factor correction, and why does it matter?

Inductive loads such as motors, transformers, and older lighting create reactive power. Correction reduces that reactive load, which can lower billed demand, free electrical capacity, and reduce heat on equipment. The U.S. Department of Energy publishes a practical primer on the topic.

What is power quality?

Power quality is the stability of voltage and current. Sags, surges, harmonics, and flicker cause nuisance trips, extra heat, and premature failure of controls and automated equipment. Correction keeps the plant electrical system efficient and reliable.

What does energy monitoring actually do?

Wireless sensors connect at a panel or a piece of equipment, often in minutes, and report use about every 15 seconds. That data finds hidden waste, supports energy-per-part reporting, and can flag abnormal loads before a breakdown.

Solar

Solar and energy storage

When is solar and storage payback reasonable?

It depends on rates, incentives, and demand charges — not a generic year count. Federal Investment Tax Credit support has been 30% through 2032. Storage can cut peak demand. EDE still starts with waste reduction; generating power for a leaky plant is more expensive than fixing the plant first.

Why consider solar if the payback looks long?

EDE typically sees solar simple payback in the 8–10 year range. Demand-charge reductions of about 4–10% are often where the extra value shows up. Solar also locks a share of energy cost against utility inflation. We model that against current rates rather than a brochure claim.

Payback

What to expect

What payback should we expect on energy projects?

It depends on the system and the utility program. Many lighting, leak, and controls projects land well under five years. We will not quote a plant-wide percentage before measurement.

Primary offer

Still have a plant-specific question?

Name, company, and the system that is keeping you up at night. We will answer from the floor, not a script.

Prefer a call? (734) 215-1133

Or call (734) 215-1133. We typically reply within one business day.

Ready to find the waste hiding in your plant?

Request a 30-minute facility energy review. No long form. No generic pitch.

Request a 30-Minute Facility Energy Review
(734) 215-1133 info@energydesignengineers.com
Call EDE Request a 30-min review