Solarity - We know how!
A project by “Solarity” and “TED” transforms the mattress manufacturing factory into an energy-independent facility
One of the most effective ways to achieve this is through the implementation of renewable energy sources (RES) and energy storage systems. A prime example of such independence is the recently completed project by Solarity at the TED mattress factory, which has commissioned a photovoltaic power plant and an industrial battery with a capacity of 15 MWh. This ensures a sustainable and independent energy future and enhanced competitiveness for the factory.
2.6 MW Rooftop Photovoltaic Power Plant – A Source of Clean Energy
The factory is equipped with a 2.6 MW photovoltaic power plant installed on its rooftops, part of a larger project for a total of 5.6 MW. This system allows for the production of a significant amount of electricity from sunlight, directly reducing dependence on the conventional power grid.
The photovoltaic panels installed on the roofs provide several key benefits:
- Efficient Space Utilization – Utilizing the rooftop areas for installing solar panels optimizes the available resources without the need for additional land development or acquisition.
- Reduced Energy Costs – The factory can use the generated energy directly in its production process, leading to significant savings.
- Eco-Friendly Production – The photovoltaic power plant not only reduces dependency on coal or natural gas but also helps lower the carbon emissions associated with the factory’s operations.
15 MWh Industrial Battery Narada/NR – The Key to Energy Sustainability
A key element of the project is the installation of a 15 MWh industrial battery. This battery plays a crucial role in ensuring uninterrupted power supply to the factory, regardless of the time of day or weather conditions. The primary function of the battery is to store excess energy generated by the solar power plant during the day and release it when production needs are highest, namely in the evening.
The facility consists of 4 modules with a capacity of 3.75 MWh each. The battery modules feature liquid cooling and are manufactured by the renowned global market leader Narada, which has over 30 years of experience. The inverter manufacturer is NR. Solarity has become the official representative and trusted service provider for both companies.
Advantages of the 15 MWh battery include:
- Energy Management Flexibility – The battery allows the factory to manage and optimize energy usage based on production needs, ensuring stable and reliable power supply.
- Reduction of Peak Loads – With the battery, the factory can store energy during periods of low consumption and use it during peak hours when electricity costs are higher.
- Backup Power – In case of unforeseen outages in the power grid, the battery can provide power to maintain the production process.
- Energy Balancing – Through intelligent management of battery processes and energy production from the photovoltaic system, the consumption profile of a large energy consumer like TED can be regulated.
Visible Energy – Smart Management with Unique Algorithms and Artificial Intelligence (AI)
One of the most intriguing aspects of the project is the implementation of specialized software, Visible Energy, which manages both the energy production from the photovoltaic plant and the storage and consumption of energy from the battery. The software is designed to adapt to the specific needs of the factory, constantly analyzing current consumption and production requirements.
Benefits of AI management through the Visible Energy system:
- Cost Optimization – The system continuously monitors and analyzes current electricity consumption while considering future needs. Based on this data, the software manages when to store energy in the battery and when to use it to minimize costs.
- Efficiency and Predictability – Thanks to the software, the factory can anticipate and prevent potential energy crises by automatically adjusting consumption according to available resources.
- Intelligent Load Distribution – The algorithms embedded in the Visible Energy system distribute energy load between the solar system, battery, and external grid, ensuring maximum efficiency in the production process.
- The system takes into account weather conditions, electricity prices, and most importantly, predefined consumption and energy distribution profiles in the grid.
Strategic Significance of the Project
The investment in the photovoltaic power plant and 15 MWh battery, combined with AI management through Visible Energy, is a strategic move that provides significant financial and environmental benefits to TED Mattresses. The factory is now capable of producing and storing a large portion of its energy, reducing its dependence on external suppliers and energy market fluctuations. This, in turn, leads to:
- Reduced Energy Costs – In-house energy production and storage reduce the need for expensive external supplies, especially during peak hours.
- Improved Competitiveness – With lower costs and greater independence, the factory becomes more competitive both nationally and internationally.
- Environmental Impact – Reducing carbon emissions from the use of renewable energy makes the factory more compliant with new environmental standards and regulations.
The project by “Solarity” and “TED Mattresses,” which includes a photovoltaic power plant, a 15 MWh battery, and intelligent management, is an excellent example of how modern technologies can lead to energy independence, sustainable development, and competitiveness. The power plant covers 100% of the factory’s energy needs during the day, while the battery meets 100% of the nighttime requirements.
This approach not only helps the factory reduce its energy costs but also demonstrates a commitment to environmental protection and the implementation of innovative technologies for better resource management.
We thank TED for trusting us to carry out the engineering and execution of this unique project.
