Commercial Solar + Battery Retrofit for Factories
Created on 09.22
Many factories already have rooftop solar systems, but solar generation and factory electricity demand do not always match.
During periods of high solar generation, excess PV electricity may be exported or curtailed. Later in the afternoon or evening, the factory may still need to purchase electricity from the grid.
Adding a Commercial & Industrial Battery Energy Storage System (C&I BESS) can help store surplus solar energy and use it when electricity is more valuable.
Why Add Battery Storage to an Existing Factory Solar System?
A solar + battery retrofit can support several applications:
- Increase solar self-consumption
- Reduce peak demand
- Shift solar energy to evening hours
- Reduce PV export or curtailment
- Support critical loads
- Provide additional capacity for EV charging or new equipment
The basic operating strategy is simple:
Daytime:
Solar PV → Factory Load → Battery Charging
Peak / Evening:
Battery → Factory Load
Instead of replacing the existing PV system, battery storage can often be added as a separate system.
AC-Coupled BESS for Existing Solar
For many factory retrofit projects, an AC-coupled battery system is a practical solution.
The existing PV inverter remains in operation, while the BESS connects to the facility's AC distribution system through a PCS.
Existing Solar PV → PV Inverter → AC Bus
Battery ↔ PCS ↔ AC Bus
AC Bus ↔ Factory Load / Grid
This approach can reduce modifications to the existing solar installation and allows the battery system to operate independently.
How Much Battery Storage Does a Factory Need?
Battery size should be based on the factory's actual energy profile, not simply the installed PV capacity.
The key information includes:
Project Data | Why It Matters |
Existing PV capacity | Available solar generation |
Hourly load profile | Determines energy demand |
Peak load | Determines PCS power |
Surplus PV generation | Determines available charging energy |
Electricity tariff | Determines peak-shaving value |
Grid voltage | Determines system integration |
Backup requirement | Determines required battery duration |
For medium-sized factories, configurations such as 125kW / 261kWh can be suitable for solar self-consumption and peak shaving.
Larger industrial facilities may require 500kWh, 1MWh or multi-MWh BESS, depending on the load and operating strategy.
More Than a Battery Cabinet
A complete commercial energy storage solution normally includes:
LFP Battery + PCS + BMS + EMS + Liquid Cooling + Fire Protection
The EMS coordinates the PV system, battery, factory load and grid to determine when the battery should charge or discharge.
Depending on the project, the system can support:
Solar Self-Consumption | Peak Shaving | Time-of-Use Optimization | Backup Power | EV Charging | Microgrid
Safety and Project Requirements
Commercial battery storage must be selected according to the destination market and project requirements.
Important considerations include:
- Battery and system safety
- Thermal runaway protection
- Fire detection and suppression
- PCS and grid compatibility
- EMS communication
- Grid connection requirements
- Local certifications
- Commissioning and after-sales support
Standards such as IEC 62619, UL 9540A, UL 9540 or local grid and fire regulations may apply depending on the market.
EnergyStar Solar + Storage Solutions
EnergyStar supports both existing solar retrofit projects and new PV + BESS projects.
Depending on project requirements, we can coordinate:
PV Modules + Inverter/PCS + C&I BESS + EMS + BOS
Available configurations range from commercial battery cabinets to multi-MWh energy storage systems.
Planning a Factory Solar + Battery Retrofit?
Send us:
Project Location + Existing PV Capacity + Load Profile + Grid Voltage + Application
We can evaluate the appropriate BESS power, battery capacity and system architecture for your project.
Applications: Factory | Warehouse | Industrial Park | Commercial Building | Farm | EV Charging | Microgrid
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