Solar Water Heaters

By Linette Page - Del Mar Times - Friday Dec. 28, 2007

After a 30-year career developing solar energy systems for others, Dr. Barry Butler founded Butler Sun Solutions in 2002 with his son Brett. Their goal was simple — to help move us toward a sustainable society, one roof at a time.

Dr. Barry Butler, owner of Butler Sun Solutions, with his patented Solar Wand Heat Exchanger.

In 1972, Butler was working at Sandia Labs on a follow-on to the Manhattan Project, and realized the decision to use such a powerful weapon was devoid of technology and fraught with politics. He changed directions and began working on the first-ever U.S. solar program to heat and cool a building. Solar energy became his passion. “Science and technology can provide the answer for people but it’s politics that decides if they can use it so I had to get politically active,” said Butler. “I’ve campaigned since 1975 to drive solar energy and personal responsibility.”

Butler moved here in 1984 to lead SAIC’s Energy Products Division. After retiring in 2002, Butler and son Brett, who has a Masters in Applied Materials, took a surf vacation to Costa Rica. While there, they decided to start a business together. Butler realized he could fund it with what he was investing elsewhere. The family agreed to an investment cap of $250,000 to insure he didn’t spend too much on what he calls “his hobby.”

With energy prices continuing to soar, the best near term opportunity was to apply all Butler knew about solar from his work and personal experience. In 1986, he built a prototype solar hot water system and installed it at his home to use, debug and enhance. This led to the heart of Butler’s business, the Solar Wand Heat Exchanger, a product that easily converts any hot water heater to solar. Butler patented this product in 2005 and has two more patents pending for related products.

His newest innovation is a self-pressurizing unit that functions like a car radiator to control system antifreeze temperature. By preventing the antifreeze from overheating, Butler reduces corrosion resulting in a 40-50 year system life.

Soon, Butler’s offering will also include a meter they designed to provide regular feedback on how much energy was created and how much CO2 was avoided. “Every new system we install prevents 2,500 pounds of CO2 a year,” Butler said. “It’s like taking a small car off of the road.”
Another core aspect of Butler’s business philosophy is to support the local economy. He buys everything he can within Solana Beach — antifreeze from Joe at Napa Auto Parts and components from Paul and Monica at Dixieline. Each assures him a steady supply.

“If you buy natural gas, only about 20 cents goes to Sempra — all the rest goes overseas to places you may or may not like,” said Butler. “If you buy our solar products, all of the revenue stays in Solana Beach and pays taxes and creates jobs.”

Butler took a measured, analytical approach to building and testing the viability of the business. All initial sales were mail order orchestrated via a website designed by Ricardo Dogue, a web designer Butler ran into walking his dog in the San Elijo Reserve. The site Dogue built allows customers to learn about Butler Sun Solutions, purchase on-line and download installation instruction and manuals.

Eighteen months ago, the Butler’s rented space in the light industrial center on Academy Drive. The arrangement worked well for Butler and building owner, Charles Kemp. Kemp wanted to downsize his own business and all of the equipment he no longer wanted — lathes, drill presses, milling machines — Butler needed and bought used, significantly lowering the capital investment.

Most of Butler’s early customers were out of state, due to tax credits in Arizona, Oregon, Colorado, and Washington. In September, California finally got in the game when the California Center for Sustainable Energy (CCSE) offered a $1,200 tax credit on top of the existing 30 percent federal tax benefit. Butler has already seen an increase in local sales.

Most of Butler’s customers are motivated to purchase by their conscience and concern for the next generation. They want to protect their children and grandchildren from the adverse effects global climate change will have on our planet. “People have lost their rudder. When they find it, they buy solar which makes me happy,” said Butler. “Personal responsibility is not just about the finances.”

Butler predicts that by 2015, gas will be $8 a gallon and we will all be forced to use less. Why wait until then? Butler encourages everyone to become personally responsible by conserving, recycling, driving fuel efficient cars and using solar.

Solana Beach resident Marilee McLean recently installed one of Butler’s solutions. “I made the investment in a solar hot water heater because I want to do all I can to make a green statement and lessen my carbon footprint,” McLean said. “I also like the concept of supporting a small local company that’s family-owned—a vanishing concept these days.” Butler is optimistic about the future and appeal of solar energy. The business has had a positive cash flow for several months and never got close to the investment cap he set. Butler now views his “experiment” a success and is preparing for growth.

In January, Butler Sun Systems will hire their first employee and cut their first payroll checks. Local conservation advocate, Cindy Davenport, will join Butler to do marketing, business development and run the office. Butler also recently became a C46 solar contactor, adding installation to their offering. “At this point, it’s clear the experiment hasn’t failed,” Butler said. “We expect to employ five to seven people by the end of next year. The business has doubled every year and there’s no reason it can’t grow to $10 million in revenue and 50-60 people in the future.”

Butler’s philosophy — there’s no reason the world can’t have a hot shower based on solar.

Butler Sun Solutions is located at 811 Academy Drive in Solana Beach. For more information, go to www.butlersunsolutions.com.