The use of solar energy is surging in South Africa and research conducted by the CSIR indicates that much of the steadily increasing installed capacity is in the commercial and industrial sectors. However, the energy produced is primarily ‘self-consumed’, which suggests that many manufacturing sites draw power directly from their solar installations and do not supplement their energy independence by using energy storage or hybrid energy solutions.
Eduardo Werninghaus, CEO at WEG Africa, says there are three main reasons for this: cost, reliability, and support.
"Manufacturers are big solar adopters. In South Africa's industrial parks, many facilities have panels on their roofs. But that's often still at the ‘surface level’. The need to justify the capital costs associated with energy projects often deters these organisations from installing more comprehensive systems. Many manufacturers would increase their use of solar if they could count on greater reliability and support, especially in energy storage and hybrid power."
Why manufacturers limit their solar adoption
Usually, solar panels coupled with an inverter can help a manufacturer supply some of its lighter operational energy needs. But to power heavier machinery and processes that can run 24/7, solar has limitations.
The most obvious is the reliance on sunlight during daylight hours; even cloudy days bring notable dips in energy generation. Another limitation relates to certain types of machinery that require slow starts or experience dramatic swings in power usage.
Many manufacturers still see solar as a complementary energy source, not a viable alternative to grid-based energy. But Werninghaus says they could do more with access to the necessary expertise that delivers and supports adequate energy solutions.
"Comprehensive solar and energy solutions are more specialised," he notes. "There are not many brands that can deliver the guarantees customers want to see before they consider taking this route. Companies like WEG have developed end-to-end capabilities offering manufacturers energy solutions that help them become fully self-reliant," Werninghaus says.
The hybrid energy future
An end-to-end energy solution gravitates around an original equipment manufacturer (OEM) that has established development, production, solution design, and deployment excellence across its value chain, from generation, transmission, and distribution to load usage and storage.
This thread of products and services is important to meet the cost, reliability, and support criteria; each area overlaps with the others, making each essential to ensure customers realise value from their energy investments. OEMs providing such integrated solutions deliver on cost, reliability and support.
Cost: Manufacturers are unlikely to invest in comprehensive energy infrastructure unless they can demonstrate a clear justification. An OEM providing an end-to-end energy value chain covers equipment and materials, engineering, and the business expertise to align with a manufacturing customer's requirements – including space usage, energy fluctuations, compliance, and deployment. OEMs like WEG also reduce costs through economies of scale and local manufacturing.
Reliability: To justify investment, manufacturers need to know their energy systems will continue to deliver. Reliability needs the right ingredients, from the type and number of solar panels, battery energy storage systems (BESS), and software to manage supply and demand to hybrid designs including generators and steam turbines. End-to-end solution providers deliver reliable energy systems because they have access to and control over the various components, skills, and innovation.
Support: Without adequate and responsive support for their installed solar and hybrid systems, manufacturing operations can still find themselves in the dark. OEMs providing an end-to-end solution control their supply chains, especially when they have an established local manufacturing footprint. They consistently produce components, develop skills, and build local networks to ensure reliable maintenance and support.
Solar is an abundant and freely available source of energy on which manufacturers can capitalise. With the right solution and end-to-end OEM support, they can limit their vulnerability to power outages. They can build a buffer against rising energy prices and play a part in Africa's energy transition.
For more information visit: www.weg.net