How a hybrid solar-battery system with automatic failover eliminated production shutdowns and saved R2.8M annually for one of Durban's leading manufacturers.
Durban Auto Parts Manufacturing operates three high-speed production lines running 18 hours a day, producing precision-machined components for the South African automotive industry. With load shedding intensifying, unexpected power cuts were causing catastrophic disruptions: CNC machines would lose their programmed positions, partially machined parts were scrapped, and each restart required 45 minutes of recalibration.
Suis engineered a purpose-built hybrid energy system designed specifically for the demands of continuous manufacturing. The solution centres on millisecond-response battery failover paired with intelligent load prioritisation to keep production-critical equipment running regardless of grid conditions.
2,400 panels across the factory's flat rooftop, oriented for maximum all-day yield. Covers 55% of daytime production energy requirements during normal grid operation.
High-power lithium-iron-phosphate batteries with 10ms switchover time, providing 3-4 hours of full production capacity during extended load shedding events.
Intelligent load management system that categorises equipment into tiers: CNC machines and compressors are Tier 1 (never interrupted), while HVAC and lighting are Tier 3 (shed first).
AI-driven system that pre-charges batteries before predicted load shedding windows and optimises solar/battery/grid mix based on production schedules and tariff rates.
Since commissioning, the facility has experienced over 150 load shedding events with zero production interruptions. The system has exceeded every performance target and transformed the factory's competitive position.
Detailed analysis of production schedules, load profiles, and critical equipment power requirements. Custom failover architecture design with 10ms switchover specification.
Sourcing of high-power LFP batteries, industrial-grade hybrid inverters, and custom switchgear from Tier 1 global suppliers with extended warranties.
Rooftop panel installation during scheduled maintenance windows. Structural reinforcement of selected roof sections to support additional panel weight.
Climate-controlled battery room construction, inverter commissioning, and integration with existing power distribution. Load prioritisation system programming and testing.
Simulated load shedding events during controlled conditions. Full production load failover testing. Staff training on monitoring systems and emergency procedures.
Before Suis, load shedding was an existential threat to our business. We were losing major contracts because we could not guarantee delivery timelines. Now, our factory runs like load shedding does not exist. The production lines have not stopped once since commissioning. Our OEM clients are impressed, and we have actually won new business because of our reliability guarantee. Suis did not just install solar panels -- they saved our business.
Let our industrial energy team assess your facility and design a zero-downtime solution tailored to your production needs.