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Case KS Design: continuing to grow despite a limited grid connection

A larger facility usually creates more room for growth: more machines, more production capacity and greater ambition. But the grid connection does not always grow with the business. KS Design experienced exactly that. After moving to larger premises, the company had more production space, but not enough electrical capacity to support that growth with confidence.

The company had also experienced several power outages. The challenge was therefore clear: how do you keep critical machines running when the electricity grid falls short?

Details

  • KS Design
  • Producer of window and door frames
  • Limited grid connection
  • Helmond, Nederland

About KS Design

KS Design manufactures window and door frames, fencing and other steel structures. Its production process relies on energy-intensive equipment, including welding robots and a laser cutting machine.

In this type of production environment, a reliable power supply is not a luxury but an absolute necessity. An unexpected interruption does not only mean that employees temporarily cannot continue working; sensitive equipment such as welding robots and laser systems can also be affected by a sudden loss of power.

Growing with a limited grid connection

Moving to larger premises created new opportunities for KS Design, but also brought an unexpected challenge. The available grid connection did not provide enough power to support the desired production capacity reliably.

And that was not the only issue. The company had also experienced several grid outages. When the power goes out, the machines stop as well. This not only leads to lost production, but can also create technical risks for certain installations.

For KS Design, it was therefore clear that simply upgrading the grid connection could not be the only solution. The company needed both more available power and greater security of supply.

The solution: additional power and backup in one system

Big Ass Battery delivered a battery solution that combines two important functions.

First, the battery provides additional power when the grid connection reaches its limit. This allows KS Design to get more from the existing connection without being immediately dependent on a heavier grid connection.

Second, the battery improves security of supply. If the electricity grid fails, the battery can temporarily take over the power supply, supported by locally generated solar energy. This helps keep critical processes running even when the grid is temporarily unavailable.

To strengthen business continuity even further, a generator was also integrated. If battery storage and solar energy are not sufficient to cover the full energy demand, the generator can start automatically. KS Design therefore has several energy sources that complement one another whenever needed.

Working smarter with solar energy

KS Design also has solar panels, creating a more robust energy system in which different energy sources can support one another.

Locally generated solar energy can be used directly in production or temporarily stored in the battery. This makes more efficient use of the available energy and reduces dependence on the electricity grid.

Where necessary, the battery, solar panels, grid connection and generator can also be coordinated with one another. This forms the basis of a smart energy system in which available energy is automatically deployed where it creates the most value at that moment.

More continuity, more room to grow

Thanks to the combination of battery storage, solar panels and an additional generator, KS Design now has a much more robust energy supply.

In practical terms, this means:

More available power without relying solely on a heavier grid connection

A greater chance of keeping critical machines running during a grid outage

More efficient use of locally generated solar energy

Greater business continuity and more room for further growth

For a manufacturing company such as KS Design, energy is therefore no longer simply about supplying electricity. It is about having the confidence that production can continue even when the electricity grid imposes limitations.

Energy as a strategic driver of growth

More and more manufacturing companies are facing the same challenge. Increasingly, it is not the available production space but the available energy capacity that determines how much room there is to grow.

A limited grid connection does not have to block that growth. By intelligently combining grid power, battery storage, solar energy and backup solutions, companies can create an energy system that is far less dependent on a single source.

Or, as we see it: energy is no longer just an operating cost. Access to power and security of supply increasingly determine whether a company can continue to produce, invest and grow.