The plastics and metal fabricator has consistently expanded its energy supply over several years. What began with a photovoltaic system on a solar carport has now evolved into an integrated energy system comprising 540 kWp of photovoltaic capacity, a STABL battery storage system with 405 kW of power and 2 MWh of capacity, and intelligent energy management. Togehter, full-service partner outarky and STABL developed a solution that optimally coordinates generation, storage, and consumption.
Molding is part of everyday business at Werner Langer GmbH & Co. KG in Meschede-Berge in the Sauerland region. Precise, high-quality components are produced from various engineering plastics using injection molding. Since 2021, the company has been applying this standard to its energy supply as well: step by step, individual components are being integrated into a smart, comprehensive system.
With an annual electricity demand of around two million kilowatt-hours, the largest battery storage system in the Meschede region to date now offers significant potential. Knut Langer, Managing Director at Werner Langer, sums it up:
The journey began in 2021 with a photovoltaic system on a solar carport. In the years that followed, further roof areas were added. Most recently, Werner Langer invested in an east-west-facing system on the office building to better distribute electricity generation throughout the day. Today, the systems together deliver 540 kWp of solar capacity. The solar experts at outarky GmbH have advised the medium-sized company from the outset and implemented everything from the initial concept through to stable operation. Outarky is a full-service partner for bespoke photovoltaic systems and energy storage solutions, supporting businesses with project development, EPC services and operational management.
However, as the company expanded its on-site power generation, the demands on energy management also increased. Not every kilowatt-hour generated could be used immediately. At the same time, the growing feed-in of renewable energy and the dynamics of the electricity markets are leading to increasingly sharp price fluctuations. It was precisely at this point that the idea arose to better coordinate generation, consumption, and storage in the future.
The missing piece of the puzzle is a battery storage system that captures excess solar power and makes it available when needed during operation. At the same time, it helps to reduce peak loads and provides additional flexibility in terms of energy procurement and trading on the spot market. Operations are managed by the “outarky.energy” energy management platform. It analyses weather data, electricity prices, load profiles, and current PV generation, taking more than 35 different parameters into account. This results in the most economically sensible charging and discharging strategy at all times.
One important application is so-called peak shaving. Since a part of energy costs depends on maximum power consumption, the storage system specifically balances out peak loads. For Werner Langer, this peak is around 480 kW. By smoothing out the load curve during high-load periods, energy costs, including reduced grid fees, can be sustainably reduced by approximately 100,000 to 120,000 euros annually.
The storage system utilises new high-performance connectors that improve efficiency, ease of maintenance, and reliability in continuous industrial operation. At the same time, the system was designed for demanding operating strategies that enable highest possible availability. “The requirements called for sophisticated operating modes with maximum uptime. With our redundant system and the energy management system of outarky, we can fully leverage our strengths in the commercial and industrial customer segment. This provides Werner Langer with a storage solution that meets the requirements of manufacturing companies while also creating room for future developments,” explains STABL project manager Markus Weiss.
When it came to storage technology, Werner Langer made a conscious decision to opt for a system from STABL. “The most impressive thing is the ‘second life’ concept, whereby either used car batteries or, at the very least, car batteries that haven’t yet been used, store our electricity,” says Knut Langer enthusiastically. In addition to the special modular multilevel inverters, a long-term and reliable product strategy was therefore a key factor in the decision.
Roman Luntscher, B2B Key Account Manager at STABL Energy and the direct point of contact for outarky, adds: “STABL supports projects throughout their entire lifecycle – from the initial planning stages through commissioning and ongoing operation. It is precisely this combination of technology, service, and partnership-based collaboration that makes the difference.”
Thanks to the battery storage system, Werner Langer will increase its self-consumption, reduce peak loads, and lay the groundwork for more flexible participation with trading in the energy market. The project thus serves as a prime example of how industrial companies can gradually evolve their energy supply, not through a single measure, but through the interplay of various technologies and use cases. Werner Langer is thus increasingly transitioning from a traditional electricity consumer to an active participant and player in the electricity market,“shaping” its own energy future step by step.
Image credit: DELIGHT FILMS GmbH
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