The story of an energy-intensive manufacturer that stopped wasting its solar power

Project snapshot

An energy-intensive operation, already generating its own power

Koval Systems is a metalworking manufacturer in Slovakia, producing security equipment such as vaults and banking technology, storage and racking systems, and automated parking solutions for customers including banks, logistics companies and local authorities.

Precision metalworking is an energy-intensive business. CNC (Computer Numerical Control) cutting, bending and coating all draw heavily on the plant’s electricity supply. Koval Systems had already invested in solar PV onsite, but the plant wasn’t making the best use of that generation. Instead, it sent some of the solar power to the grid. And when generation fell short of what production needed, the plant still drew from the grid to cover the gap.

Solar power that wasn’t being fully used

With energy-intensive production and growing pressure to show real progress on sustainability, Koval Systems needed a way to put more of its own solar generation to use, rather than exporting it or relying on the grid to fill the gaps. The company put the project out to tender, looking for a partner with the expertise and track record to match its scale.

A battery system managed by an intelligent energy platform

Wattstor was selected on the strength of our track record. We designed, delivered and commissioned a 1,509 kW / 5,016 kWh battery energy storage system (BESS), working alongside the solar array already on site.

Podium, our energy management system (EMS), controls the battery and manages the site’s energy automatically, without manual intervention, so more of the solar power generated onsite gets used rather than exported to the grid and lost. Podium sits behind every Wattstor project, across more than 200 installations across Europe.

We supported the project from initial design through to installation, then connected the new system safely to the grid.

Six months, from design to commissioning

• Detailed design of the BESS and Podium EMS solution
• Delivery, installation and commissioning of a 1,509 kW / 5,016 kWh battery energy storage system
• Integration of the Podium EMS software
• Connecting the system safely to the grid

The result: less waste, more self-sufficiency

Since the BESS controlled by Podium went live, Koval Systems makes fuller use of the solar power it generates, rather than losing it to the grid. That’s strengthened both the plant’s energy self-sufficiency and its sustainability.

• Greater use of onsite solar generation for the plant’s own production
• Improved energy self-sufficiency
• A stronger ESG position for the business
• A six-month delivery of a large-scale installation

Chosen for expertise that matched the scale of the project

“Koval Systems is a strong player in metalworking, and this industry naturally brings high electricity consumption. The company decided to install solar PV and battery storage, and for delivery it was looking for a partner with the expertise and track record to match the scope of the project. That’s what Wattstor was able to offer.”

Patrik Pinkoš, Head of Sales for Europe, Wattstor

Not getting full value from the solar power you already have?

If your site has solar in place but isn’t seeing the full benefit, whether that’s down to sizing, timing or control, get in touch with our team today.