25%
.....
Saving on energy costs
>30%
.....
Increase in production
100%
.....
Reduction in diesel consumption
Overview
ElectroMechanica’s (EM) production facility faced frequent load-shedding, disrupting the manufacturing process and damaging production equipment. These interruptions led to significant delays, inefficiencies, and higher operational and maintenance costs.
When initially installed, the existing diesel generator was not designed to accommodate the increased load of the relocated production line. As a result, it couldn't maintain power delivery for the entire site during outages, necessitating the lines to be purged and restarted after every switchover. This limitation led to increased operational costs and proved unsustainable.
“Recognising the urgent need to maintain smooth production and reduce costs, EM initiated a project to implement a hybrid inverter and battery system to provide a seamless, uninterrupted power supply, boost operational stability, and improve safety.”
The Challenge
Challenge 1
Sustaining power supply through grid outages
The primary challenge was achieving temporary grid independence using the existing infrastructure. We identified that reliance on the existing diesel generator system led to production downtimes during power switchovers and increased operational costs.
Challenge 2
Inefficiency and downtime
Frequent power outages, particularly two-hour load-shedding periods, caused significant production downtimes. With production halted during these periods, the extrusion lines required purging and restarting after each power cut, resulting in approximately five hours of downtime over twelve hours (if two 2-hour load-shedding sessions were experienced). This inefficiency disrupted productivity and placed excessive strain on equipment, accelerating wear and tear and increasing maintenance requirements.
Key aspects of the solution
EM led the implementation of the new system by collaborating with Freedom Won and Hooray Power. Their expertise was essential for handling technical challenges and ensuring smooth integration of all components. The project began with a thorough analysis of our power needs. EM’s engineering team documented the existing setup and gathered data from other sites.
Accurate specification and hardware design
EM and Hooray Power’s engineering teams worked closely to finalise the specifications, ensuring the system could meet current demands by utilising existing infrastructure while allowing for modular scalability in the future.
Comprehensive control and monitoring
Implementing an advanced Energy Management System, selected and integrated by EM, enabled comprehensive monitoring and control of energy production, storage, and consumption, ensuring optimal system performance. The EMS provided remote monitoring capabilities, allowing our technical team to oversee the system's performance in real-time and address issues promptly, ensuring continuous operation.
With other EM sites already enjoying a high level of energy independence, the EMS can be rolled out to these locations to provide a consolidated view of total energy usage and production across the company. Looking ahead, we plan to scale up the system to meet additional power needs and expand production capacity.
“During the switchover, EM led the effort to successfully overcome technical challenges such as firmware and compatibility issues. The collaboration with Freedom Won and Hooray Power was crucial in quickly and efficiently resolving these challenges.”
Future scalability and efficiency optimisation
EM continues to work closely with Freedom Won and Hooray Power, using their expertise for ongoing improvements and future projects which we anticipate will include:
System expansion: Increase capacity by adding a 500kWh battery and an additional 300 kWp of PV solar generation to the site. Implement an EV charging solution for a future electric vehicle fleet and explore additional secondary grid-tied PV generation opportunities.
Load reduction measures: Install variable frequency drives (VFDs) for effective load management, utilise power factor correction (PFC) for power quality optimisation, and integrate with our SCADA system (VTScada) for advanced site load management and control..
Energy export: Export surplus energy production to the municipal grid to help alleviate the national energy crisis and reduce our grid energy charges.
Tech Specs
| Equipment | Benefit |
|---|---|
| 245kWp Solar Panels | Efficient solar energy capture and conversion. |
| 2x 50kW Grid-Tied inverters with 80kWP connected PV | Additional component of the energy system. |
| 1x Freedom Lite Commercial 500/400 HV+ | Reliable power storage and supply. |
| 500kW Inverter Incl. Transformer | High efficiency and stability for power conversion. |
| 200kW diesel generator | Back-up component of the energy mix. |
| 5x 55kW MPPT Modules | Maximises power output under various conditions. |
| Lightning Protection System Supply & Installation | Protects the system from lightning-related damages for enhanced safety and risk mitigation. |
| PV Combiner Panel | PV strong combing and surge protection. |
| Power Bypass & Distribution Panel | Ensures reliable power distribution across the facility in emergency situations. |
Setting a new industry standard
The hybrid inverter and battery system at our Wynberg facility is now fully operational, providing a reliable backup power solution to mitigate the effects of grid outages on our business operations. This seamless power supply has eliminated delays from generator switchovers, cut diesel costs, and boosted production efficiency by eliminating downtime.
Usage comparison (June 2023 vs June 2024)
We have seen a significant transformation in the energy consumption profile at our Wynberg site. The advanced hybrid inverter and battery system and solar energy contributions now comprise a significant portion of the energy mix.
This shift has allowed for a marked reduction in reliance on Eskom mains power, effectively eliminating the need for the diesel generator as a backup source. Our optimised power supply has resulted in enhanced energy efficiency, reduced operational costs, and increased resilience against grid outages.
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Load comparison (June 2023 vs June 2024)
We have also seen a noticeable decrease in peak loads, which has enabled a more balanced and consistent energy distribution across the facility's various operational sectors. The system's integration of solar power and energy storage has not only stabilised the energy supply but also minimised the impact of load-shedding events.
This has resulted in significantly reduced production downtimes, improved equipment utilisation, and enhanced overall productivity. Our hybrid system forms the foundation of a robust and scalable energy infrastructure that meets current demands while being adaptable for future expansion.
Demonstrating cutting-edge solutions and benefits
We now showcase the new system to potential clients, emphasising its benefits and seamless integration. Demonstrating operational improvements and cost savings, this solution sets a benchmark for both innovation and reliability. EM’s balance of system products not only showcases our integration capabilities, but also supports efficient energy consumption and the use of sustainable energy sources wherever possible, promoting a more sustainable future.
Empower Your Business with Uninterrupted Energy Solutions from ElectroMechanica
At ElectroMechanica, we provide customised and scalable hybrid energy systems designed to reduce maintenance costs, minimise downtime, and achieve energy independence. Partner with us to future-proof your operations and unlock the potential for uninterrupted production.
Contact us today to discover how we can transform your energy infrastructure.