The Holiday Season, especially in Western cultures, has become synonymous with magic. To create this enchanting atmosphere, we decorate our homes, offices, and stores, and it’s not unusual to see cars covered in twinkling lights. As a manufacturing company, we recognize that all these decorations, every festive meal, and even the boxes the ingredients are shipped in, are manufactured. It’s a fun and proud note to be a part of this holiday magic. However, we can’t help but notice that this festive season often comes with increased energy consumption. In this blog, let’s explore the fascinating relationship between manufacturing and the energy demands of holiday celebrations.
How To Light A Tree
When I was a kid, my mom had a very specific and non-negotiable process for decorating our Christmas tree. It went something like this:
- Set up the bare tree.
- String pre-tested, working lights around the tree.
- Add garlands, making sure they are evenly distributed.
- Place the balls in clusters and singles.
- Decorate with ornaments and embellishments.
- Top the tree with the star.
- Turn off the room lights and marvel at the warm, orangey glow of the incandescent wonder that was our tree. If you’re feeling the holiday vibe, sing carols!
At no point during these festivities did we ever “check the energy bill.” However, as an adult, I can’t help but wonder how much energy we were consuming during our holiday traditions. Let’s delve into the cost of using incandescent holiday lighting.
Traditional incandescent holiday lights are relatively energy-hungry. A string of 100 incandescent mini-lights, for example, can consume around 40 to 100 watts or more, depending on the bulb’s wattage. This means that if you have multiple strings of these lights, the energy usage can add up quickly. Let’s get nerdy with this for a moment…
Keep in mind that holiday light energy consumption depends on how long you leave the lights on. To calculate the energy usage for this specific situation, we will use the following standard formula:
Energy (in watt-hours) = Power (in watts) x Time (in hours)
So, one incandescent string at a conservative rating of 50 watts, if run in the evenings at home for 8h a day, for about 30 days would have the equation: (8h/day x 30 days) x 50w = 12,000 Watt-Hours. My tree usually had 3 strands. That’s 36,000 Watt-Hours, or 36kWh, of new, holiday energy use. The US average cost of these 3 string lights in 2023 is about $8.26USD of new expenses.
Let’s take this a bit further… How many homes in the USA are putting lights up? Well, according to Pew Research, approximately 92% of Americans celebrate Christmas. We’ll take that to mean 92% of households – and that means 118,174,000 households probably are running lights! If everyone were running incandescent like my childhood home did the stats feel staggering:
- 4,254,264,000 Watt-Hours are powering our collective Christmas Trees
- $976,117,240 is an approximate bill being paid to light up the holiday shrubbery
WHAT? What does this mean for the environment?
According to the US Government Energy Information Administration, the electric grid causes 0.855lbs of CO2 emissions for every kW expended. If that’s the case, our holiday light magic is causing 3.63B pounds of carbon emissions. That said, it’s only 1.8M Metric Tons of emissions and the grid is responsible for 1.8B tons. All this means is that, if our assumptions are right, we’ve discovered that holiday lights account for about 0.1% of US Carbon Emissions.
I Bought LED Lights
A few years ago, a bulb blew out on a set of my lights, and it happened to be the kind that could ruin the entire string. I decided I wasn’t going to deal with that frustration again, so I made the switch to LED lights. Not only did they come in a bright daylight color, which I regret now because I like the old-timey feel of the incandescent orange-yellow, but they were also energy-saving. The statistics speak for themselves.
A string of LED lights consumes significantly less energy compared to their incandescent counterparts. Let’s run the same calculations as before, factoring in how many households use LED lights and the number of days these lights are in use. A string of 100 LED lights typically uses around 4 to 10 watts, which is significantly less compared to incandescent lights. LED lights have become increasingly popular due to their energy efficiency and durability.
This is pretty easy math: assuming 5w instead of 50w, we’ve realized a 90% savings. Were we all to shift LED’s we’d pay $0.83 per season in electricity AND save 0.09% of all US Carbon Emissions. It’s small, but it’s big, too.
Connecting Alternative Energy to Holiday Energy Consumption
While we all want to celebrate the holidays and come together, it’s also crucial to consider how we can do so with a lower energy impact. I want to consider a future where LED-type technologies are universally adopted. Consumption of electricity, in this thought experiment, would reduce by 90%! That’s a very interesting goal. But what if, at the same time, we change energy generation to clean, sustainable creation as well? We’re meeting energy savings halfway and accomplishing something so much greater. And, isn’t that what we’re doing? Isn’t that the mission we’re on?
Can I tell you a secret? This blogger is a capitalist, red voter with a reasonable redneck. I shouldn’t, by stereotype, be excited about electric cars or Alt-Energy, but I am. Re:Build Optimation is a champion of it and rightfully so. The progress being made in science and technological innovation to ever increasingly arrive at new ways to power the world we’ve created. Progress sometimes is slow, sometimes it is messy, and sometimes it doesn’t check all the boxes, but as we all move forward and learn together we do make remarkable progress. That’s why Optimation sees a connection between the magical holiday lights and our celebrations and the promising future of energy consumption. It tells us a story and encourages us towards new ways of powering the magic in future celebrations.
Our Contribution: Solar Tech, Wind Tech, and Battery Technologies
In the rapidly evolving landscape of solar energy, Traditional Photovoltaic (PV) panels have been the stalwart players, providing a reliable source of renewable power for homes, vehicles, and industrial applications. However, the solar energy revolution is witnessing the emergence of innovative technologies, and one such promising option is Perovskite solar panels. These panels offer a more cost-effective alternative to traditional silicon-based cells, boasting advantages such as high defect tolerance, band gap tunability, and cost-effective fabrication. Perovskite solar cells, with their thin-film technology and crystallographic structure, have demonstrated superior performance, absorbing high-energy blue photons efficiently. The development of tandem silicon-perovskite stacked cells has the potential to boost power conversion efficiency by 30%.
As solar technologies advance, solar heating systems are also making strides in efficiency. The ability to capture and utilize sunlight for heating purposes is becoming more refined, contributing to the broader spectrum of solar applications. The continuous exploration of alternative materials and manufacturing methods is crucial to overcoming the challenges associated with the solar energy value chain, from raw materials like quartz to the production of solar cells and the assembly of PV modules.
Amidst these advancements, Re:Build Optimation stands out as a key player in the solar energy industry, offering a comprehensive suite of resources and expertise. With a team of 200 engineers and industrial trades workers, along with 140,000 feet of fabrication space, Re:Build Optimation is well-positioned to tackle the complexities of solar cell manufacturing. The company’s focus on Roll-to-Roll (R2R) technology is particularly noteworthy, as it promises to dramatically reduce the cost of semiconductor manufacturing methods. R2R processing, also known as web processing or reel-to-reel processing, is a substrate-based manufacturing process that enables continuous, high-throughput, and cost-effective production.
Re:Build Optimation’s expertise in R2R processing extends to the development and prototyping of large-scale, low-cost manufacturing facilities for solar energy products. The company’s media conveyance facility, along with its web coating, handling, and converting experience, positions it as an ideal partner for clients looking to implement R2R technology. The R2R process, which involves the continuous deposition, phase conversion, and crystallization of solar cell layers, has proven to be a game-changer in achieving high-volume production at lower costs.
Notably, Re:Build Optimation’s capabilities extend beyond solar cell production to encompass various renewable energy projects. The company has a successful track record in biofuels, ethanol, jet fuel, hydrogen, methanol, green plastics, wind turbines, plant and food preservation, batteries, and storage systems. The breadth of their experience makes them a valuable resource for clients seeking seamless, cost-effective, and timely completion of their renewable projects.
In addition to manufacturing support, Re:Build Optimation provides crucial services in flexible web property precision measurement for R2R manufacturers. This involves measuring key web properties like friction, tensile properties, stack modulus, surface roughness, and nip system diagnostics. These measurements ensure robust and reliable web-handling processes, contributing to the overall success of solar manufacturing projects.
In conclusion, as the solar energy landscape continues to evolve, Re:Build Optimation emerges as a key player, offering a combination of expertise, resources, and a focus on cutting-edge technologies like Roll-to-Roll processing. With a proven track record in various renewable energy projects and a commitment to providing end-to-end solutions, Re:Build Optimation stands as a valuable partner for those looking to navigate the complexities of the solar energy industry and achieve success in their industrial applications.
Battery Energy Storage Technology
Lithium-ion batteries have established prominence in energy storage, particularly with the increasing prevalence of electric vehicles, such as those produced by Tesla. The modular structure of lithium-ion batteries, composed of smaller cells, facilitates scalability, making them versatile for various applications, including electric vehicles, grid enhancement, and backup power. Re:Build Optimation acknowledges the strategic importance of lithium-ion batteries, fostering collaborations with manufacturers to explore advancements in “super batteries.”
Re:Build Optimation actively engages in the assembly, testing, and software management of these advanced systems. The term “super batteries” encompasses a range of advanced energy storage technologies, including lithium-sulfur batteries, solid-state batteries, graphene-based batteries, flow batteries, metal-air batteries, lithium-air batteries, and nanostructured batteries, each offering unique advantages.
The exploration extends to alternative battery technologies to address challenges related to lithium mining and geopolitical implications. Zinc-air batteries emerge as a potential alternative, utilizing domestically sourced zinc with high energy densities and lower manufacturing costs. Re:Build Optimation’s venture into zinc-air battery technology is positioned as a project aimed at exploring innovative solutions.
In addition, hydrogen electric vehicles represent a growing trend, illustrating the versatility of electric propulsion through either batteries or fuel cells. The transition toward hydrogen internal combustion engines as an alternative to traditional gasoline or diesel engines aligns with the evolving landscape of energy generation technologies. In the domain of battery production lines, Re:Build Optimation’s expertise is evident in transformative projects, including the design of complete battery production lines and the repurposing of equipment for a New York-based battery manufacturer. The company’s ability to address complex challenges is showcased in the creation of comprehensive battery production lines tailored for specialized military and first responder applications.
In roll-to-roll manufacturing, Re:Build Optimation excels in coating materials for specific battery performance characteristics, optimizing battery production processes. The company demonstrates proficiency in pinpointing opportunities for process enhancements, empowering manufacturers to elevate product quality and boost production efficiency. In the realm of automation, Re:Build Optimation plays a significant role in modern manufacturing processes, streamlining production, and enhancing overall efficiency.
In conclusion, Re:Build Optimation is positioned as a player in the energy storage sector, emphasizing collaboration with manufacturers to explore advancements in battery technology. The company’s involvement in the assembly of advanced energy storage systems, exploration of alternative battery technologies, and expertise in battery production lines and automation underscores its commitment to contributing to the evolving landscape of energy storage.
Our Commitment to Each Other
This holiday season, Optimation is reminded that our commitment to manufacturing is, at its core, a commitment to each other. Every time a manufacturer discovers a new, better, and sustainable way to produce something, the world gets a little better. While holiday lights do not pose a specific energy crisis, they serve as a reminder of our collective commitment to help the energy industry innovate towards sustainable, renewable energy sources.
The magic we find in our work as manufacturers is an integral part of our collective human experience. It allows us to maintain the enchanting traditions and rituals that bring us together during the holidays. As we continue to progress towards a more sustainable future, we can preserve the magic of the holiday season, ensuring that future generations can celebrate the same way we do today.