INDUSTRy 4.0 / SMART FACTORIES
manufacturing sector is already ahead of many others, in terms of its consideration of carbon emission reduction. As one of the most energy- intensive sectors with a vital share of the route to post-Covid economic growth, this is both positive and necessary. Investors and shareholders are increasingly requiring that companies show, clearly and with a scientific basis, that they are committed to net zero and that they have plans to make it a reality. The general public’s awareness of greenwashing means that companies without a clear picture of how to achieve net zero may be risking reputational harm as well as facing productivity problems.” The growing shift to net zero is evident in the
transition to electric vehicles (EVs), and this seems an obvious option for companies to reduce carbon emissions, through switching fleets to EVs. Legislation supports this, with non-EVs set to be phased out by 2035. A note of caution should be injected, as the significant increase in electricity necessary for EV charging could mean that companies planning this as part of a carbon reduction strategy may face penalties. If the required energy is a significant issue for their Distribution Network Operator (DNO) then such a plan may be either prohibitively expensive or refused, altogether. However, as Morris notes, there is a potential solution to this problem. This solution may help companies harness the benefits of Industry 4.0 while also helping manufacturers work towards net zero. Morris explains, “On-site EV charging is going to be critical for manufacturing, and for logistics and handling. At Powerstar, we have been working with customers wishing to introduce a power resilience ethos. As part of this strategic shift, renewable energy generated on-site - solar power from a roof array at a manufacturing plant, for example - can be stored for use as required. EV fleet charging is not determined by when the sun is shining, rather the energy generated is reserved for when the company needs it. And there is, potentially, no additional requirement from the Grid. Our R&D at Powerstar is focused on this concept of power resilience, and an increasing number of companies are installing our Battery Energy Storage Systems.” A Battery Energy Storage System (BESS) can function at the heart of a smart microgrid,
The UK energy mix forecast
working to mitigate against the power disruptions that look set to become increasingly common - brown-outs and damaging voltage fluctuations, more so than complete black-outs. As we collectively move away from fossil fuels and as the demand for energy from the Grid increases, such a system both protects and forms a part of an overall Industry 4.0 approach and a smart factory set-up. Morris explains, “An integral aspect of a BESS is its role in providing an uninterruptible power supply. Critically, though, while traditional UPS systems would only protect specified, individual equipment, the BESS can protect a site in its totality. This includes the software, plant and equipment that is increasingly required to work in an interconnected way to ensure productivity. And, as part of a carbon emission reduction programme, where a traditional UPS will lose between 10 and 15 percent power while standing idle, battery energy storage loses around one percent. Add to this the capacity to store renewable energy generated on- site, for use in EV charging or even for sale back to the Grid as an additional revenue stream. The balance between Industry 4.0 and a world shifting to net zero can now be seen in an increasingly positive and less daunting light.”
One area that will only grow as Industry 4.0
develops, is digital twinning - and manufacturing is certainly the sector furthest ahead in both the development and deployment of digital twins. Complex infrastructure projects, including the implementation of new digital equipment and the rollout of a site-wide power resilience strategy, can be digitally modelled in real-time before being commissioned. This approach, modelling and trialling a system adjustment or an entirely novel process, helps ensure that any solution operates as intended across a wide range of internal as well as external factors. It allows for the simulation of every conceivable event to ensure the project will operate as intended at all times. Morris concludes, “For manufacturing, digital
twinning ensures that increasingly complex overhauls of existing equipment as well as further digitisation of processes and assets can be implemented without risking unforeseen downtime. As part of a power resilience strategy, digital twinning can be vital. For example, Powerstar recently developed and implemented a battery energy solution, underpinned by digital twinning, for a customer whose client required sophisticated R&D. Our customer would have found this project difficult to fulfil within the terms of their Network capacity, given the energy required for the new facility. Our solution was, effectively, a digital twin - but one running as a vital part of project implementation, not solely used as a model to test feasibility. The modelling and simulation data was provided to the customer’s Distribution Network Operator and was instrumental in the project being approved to proceed. It is projects such as this that lead us at Powerstar to continue our investment in R&D focused on power resilience. Increased digitisation and connectivity, coupled with the necessity to reduce carbon emissions, are opening up new horizons for British manufacturing.”
Power disruption examples
Powerstar
www.powerstar.com
info@powerstar.com 0333 230 1327
16 OCTOBER 2021 | FACTORy&HANDLINGSOLUTIONS
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