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05 / 06 · Manufacturing · 2024

Regional Specialty Manufacturer

Allentown, PA

Solar + 500 kWh storage system designed around demand-charge management. Storage discharges during peak windows; demand-charge reduction pays back in under 7 years.

Regional Specialty Manufacturer — Manufacturing solar installation
System size
1.2 MW
System size
1.2 MW
Panels
2,800
Annual production
1.5M kWh / yr
CO₂ offset / yr
1,050 metric tons / yr
Payback
5.8 years (combined)
Year
2024
The challenge

What the customer brought us.

Specialty metal-fabrication manufacturer with predictable shift schedule but high demand charges — peaks of ~850 kW on hot summer afternoons drove the demand-charge line above $17,000/month. Solar alone wouldn't dent it because cloud cover dropped output during peak windows. Owner wanted both kWh savings AND demand reduction.

The solution

How we engineered around it.

Solar + 500 kWh lithium battery storage paired through one EMS. Storage continuously monitors facility load and discharges to keep demand under 540 kW threshold. Solar charges the battery during sun hours; battery covers the gap when clouds hit. Storage qualified for the standalone-storage federal ITC.

The outcome

What's actually happening on the meter.

Peak demand cut from 850 kW to 540 kW (37% reduction). Demand-charge savings: ~$74K/year on top of energy savings. Combined monthly bill reduction: ~50%. Storage standalone payback under 7 years even before counting solar synergies.

System spec

The hardware on the building.

panels
Tier-1 mono PERC 555W modules
inverters
Hybrid solar + storage inverters
mounting
Mixed rooftop + ground-mount overflow
battery
500 kWh lithium-ion w/ EMS
Timeline
Contract to PTO: 9 months
First peak summer with the system live and our utility bill was the lowest July I've seen in fifteen years. The storage is the unsung hero.
Plant Manager
Specialty Manufacturer, PA

Testimonial pending client release

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