Industrial Demand Charge Reduction System (Kansas)
Overview
CDL Electric operates a large-scale manufacturing facility in Pittsburg, Kansas, serving the railroad industry with signal crossings, control houses, and switching equipment.
Across two primary buildings, the facility experiences significant peak demand swings driven by manufacturing operations. With monthly peak demand ranging from approximately 250 kW to 500 kW, demand charges had become a major and unpredictable operating expense.
To reduce utility costs and improve energy cost predictability, the site deployed a behind-the-meter solar and battery energy storage system designed to shave peak demand while supporting day-to-day manufacturing operations.
Requirement
Deploy a behind-the-meter solar and battery energy storage system capable of reducing monthly peak demand, improving energy cost predictability, and supporting industrial manufacturing operations.
Solution
A targeted demand-shaving system was deployed using Discover AES 210 battery systems, Sol-Ark inverters, and rooftop solar PV.
The system combines 4 Discover AES 210 commercial battery systems with 2 Sol-Ark 60 kW inverters and a 148 kW rooftop solar array. An integrated control strategy allows the system to automatically reduce peak demand by discharging stored energy during high-load periods.
The system was designed to offset approximately 100 kW to 120 kW of monthly peak demand while operating seamlessly alongside the facility’s existing utility service.
Installation and commissioning were straightforward, supported by pre-configured programming and commissioning assistance.
Application
Demand charge reduction, solar self-consumption, power factor support, and industrial energy cost management.
System Details
Discover Products
- 4 × Discover AES 210HV battery cabinets
- 4 × LYNK II communication gateways
Other Products
- 2 × Sol-Ark 60 kW inverters
- 148 kW rooftop solar PV system
- Integrated demand-shaving control strategy
Outcome
The completed system delivers measurable utility cost savings by reducing peak demand without disrupting manufacturing operations.
Key results include:
- Monthly peak demand reduced by approximately 100 kW to 120 kW
- Annual utility costs reduced from approximately $200,000 to approximately $140,000
- Estimated annual savings of approximately $50,000 to $60,000
- Fully automated peak shaving
- No disruption to manufacturing processes
- Scalable platform for future expansion
The customer experience was positive, with the installation described as smooth, easy, and performing well.
By turning a major operating expense into a more controllable energy strategy, CDL Electric improved cost predictability while building a scalable foundation for future energy management.
What Makes This Project Unique
Clear financial impact
The system directly targets demand charges, reducing peak demand and lowering annual utility costs.
Industrial manufacturing application
The solution supports two active manufacturing buildings without disrupting production.
Automated peak shaving
The system responds to demand peaks automatically, helping reduce costs without adding operational complexity.
Solar + storage value stack
Rooftop solar offsets daytime consumption, while battery storage helps reduce high-demand utility charges.
Scalable energy platform
The modular AES architecture supports future expansion as site requirements evolve.
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