Optimizing the self-consumption of renewable energy in factories and ensuring grid stability with the ESiP Analyzer
When properly planned and sized, energy storage systems in production (ESiP) can optimally utilize renewable energy produced in-house. The ESiP Analyzer, introduced at the ees Europe trade fair in 2025, has since successfully proven itself in real-world applications with utilities and industrial companies: the tool helps factories improve the integration of renewable energy and reduce peak loads. Experience to date shows that targeted simulations and optimized operating strategies can, in some scenarios, enable the use of close to half of the electricity generated on-site. Grid stability also benefits from the “smoothed” consumption resulting from the use of storage systems.
Efficient energy storage planning with the ESiP Analyzer
The ESiP Analyzer primarily supports energy management in manufacturing companies. In addition to classic peak load reduction, the tool enables evaluation of various use cases. It covers various energy storage technologies from the machine level to the factory level and supports companies in planning, integrating, and operating customized energy storage solutions. A key feature of the tool is the development of specific design methodologies for different application scenarios. In addition, important operational factors such as system efficiency and specific production parameters are incorporated into the simulations. The goal is not only to support companies in selecting the appropriate storage technology, but also in developing optimal operating strategies for long-term, efficient, and cost-effective use.
Benefits and application options
The ESiP Analyzer demonstrates its capabilities particularly in real-world application scenarios, even when planning information is partially incomplete. Missing values in load profiles or yield data can be reliably supplemented through appropriate scaling and simulations, ensuring that meaningful analyses remain possible. Furthermore, the analyzer offers additional perspectives, for example, through the combination of different applications (e.g., participation in energy markets, emergency power supply, or efficiency improvements through energy fed back at the machine level).
Interested companies can choose how they would like to use the ESiP Analyzer. For a comprehensive analysis of the current state and recommendations – including consulting services provided by Fraunhofer IWU experts – custom project agreements are available. For ongoing use, licensing agreements can be concluded.
Fraunhofer IWU at “The Smarter E Europe” in Munich: ESiP Analyzer and outlook on resource-efficient disassembly of traction batteries
From June 23 to 25, 2026, Fraunhofer IWU will present the current state of its innovative design and simulation tool at the “The Smarter E Europe” trade fair, on the joint booth of Saxony Economic Development, using real-world application cases.
Fraunhofer IWU will also provide an outlook in Munich on a pilot plant – designed together with EDAG Production Solutions and currently under construction in Chemnitz—that will be capable of automatically disassembling traction batteries down to the cell level. Using AI technologies and an analysis module to assess their “state of health,” functional components will be identified and routed to suitable reuse pathways. The new facility is scheduled to begin operations in August. Going forward, it will also demonstrate the economic feasibility of disassembling new systems developed with a design-for-recycling approach. Such a system is demonstrated with a battery module that can be disassembled without causing damage.
The ESiP project "Energy Storage in Production" was funded by the German Federal Ministry for Economic Affairs and Climate Action. Further partners in ESiP: EA Systems Dresden GmbH, Karlsruher Institut für Technologie (KIT), Skeleton Technologies GmbH, Power Innovation Stromversorgungstechnik GmbH.
The dismantling plant for active (functional) traction batteries is co-funded by tax revenues based on the budget passed by the Saxon State Parliament.
Wissenschaftlicher Ansprechpartner:
M.Sc. Hanns-Martin Strehle
Fraunhofer Institute for Machine Tools and Forming Technology IWU
Reichenhainer Straße 88
D-09126 Chemnitz
Hanns-Martin.Strehle@iwu.fraunhofer.de
+4937153971143
Originalpublikation:
https://www.iwu.fraunhofer.de/en/press/2026-optimizing-the-self-consumption-of-renewable-energy-in-factories-and-ensuring-grid-stability-with-the-esip-analyzer.html
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