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HUA-X battery project reference / Near Ingolstadt, Bavaria, Germany

Storage Reduces Peak Demand at a Bavarian Automotive-Parts Factory

A Bavarian stamping plant used a PowerFac 250 kW / 522 kWh system to reduce maximum demand from 1.42 MW to 1.19 MW and combine demand savings with daily energy shifting.

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A technician beside a double-width HUA-X energy storage cabinet outside a Bavarian factory.
Illustrative project scene.

Short production peaks with a lasting cost

Three 800-tonne presses created sharp load changes at an automotive-parts plant near Ingolstadt. Maximum demand reached 1.42 MW. With an annual power-charge rate of approximately €118 per kW, the cost of these peaks continued to affect the bill beyond the production event itself.

The plant needed a system that could respond to changes in factory load and also shift energy between lower- and higher-price periods.

Load-following power with a 522 kWh battery

A liquid-cooled PowerFac 250 kW / 522 kWh system was installed with two-level battery management and active balancing. The PCS followed the plant load to reduce peaks, bringing maximum demand down to 1.19 MW.

The system also operated across electricity-price periods of €0.19 and €0.31 per kWh. The project used one daily energy-shifting cycle on approximately 250 working days a year.

Factory-specific economics

Demand-charge savings reached approximately €27,000 a year. Energy shifting contributed around €58 per working day, or €14,500 annually. The equipment cost €68,000 landed, with installation and commissioning bringing total investment to €79,000; the resulting simple-payback estimate was 1.9 years.

Preparation of the project's grid-connection and supporting documentation took seven months. Grid connection was therefore a significant part of the schedule alongside equipment procurement and site work.

Project FAQ

Questions about this project reference

Configuration, application and operating conditions for this project.

Why did the stamping plant need both power and energy capacity?
The presses created sharp load peaks, so the system needed enough power to reduce maximum grid demand. Daily energy shifting also needed sufficient stored energy between tariff periods. The 250 kW / 522 kWh installation served both duties, with the operating schedule allocating battery capacity between them.
What supports the project's 1.9-year simple-payback estimate?
The project combined approximately €27,000 in annual demand-charge savings with €14,500 from energy shifting against a €79,000 installed investment. The latter used about 250 working days per year. A plant with different power charges, operating days or tariff spreads will have different economics.
Why was grid connection a significant part of the schedule?
Preparation of connection and supporting documentation took seven months in this project. Equipment delivery alone therefore did not determine the installation timetable. The connection process depends on the site's electrical arrangement and the applicable network requirements; seven months is this project's experience, not a standard lead time.

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