E-Flex
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Energy Flexibility and Savings for Decarbonisation of Industrial Processes of SMEs
Small and medium-sized industrial enterprises increasingly generate their own electricity via photovoltaic systems. However, their existing production and energy management systems are typically rigid and not designed to respond to the volatility of renewable energy supply. Feed-in tariffs are declining, making self-consumption more economically attractive, yet companies often lack the digital infrastructure and planning tools to align energy usage with renewable availability. As a result, PV systems are frequently underutilised, especially on weekends, and opportunities for energy and cost savings remain untapped. There is an urgent need for practical, scalable solutions that increase operational flexibility and integrate energy considerations directly into production planning.
“What we’re doing with E-Flex is helping companies get a grip on their energy use - not just cutting costs, but actually planning smarter with the energy they already have. It’s about making renewables really usable in daily operations and building the flexibility to adapt when it matters most.”
The project begins with a detailed audit of current energy usage and production processes at Fuchshofer and Wessely. Based on these insights, a full sensor network is deployed to gather high-resolution energy data, which is then analysed to identify consumption patterns and flexibility potential. A virtual demo environment is created to simulate energy flows and test optimisation strategies. In parallel, concrete process innovations are implemented, such as automated tool dressing for unsupervised machining and improved waste heat recovery.
Building on this foundation, a Decision Support Tool (DST) is developed to dynamically align production schedules with renewable energy availability, forecasted PV output, energy prices, and operational constraints. The DST will support production managers in making real-time decisions that lower energy costs, reduce CO₂ emissions, and increase renewable self-consumption, all without compromising productivity. The final phase focuses on pilot testing and adapting the E-Flex framework and DST for easy transfer to other SMEs.
Milestones
- Completion of the energy system audit and identification of efficiency and flexibility gaps at both use case sites
- Full deployment of the sensor network and development of validated energy flow models for simulation purposes
- Completion of the DST prototype, capable of generating optimised production schedules based on forecast data and flexibility metrics
- On-site pilot testing of the E-Flex system and development of a transfer strategy for broader SME application
The project is expected to demonstrate measurable reductions in energy costs and CO₂ emissions at the pilot sites. It will result in a tested and transferable framework with high rollout potential among SMEs, supporting broader decarbonisation and competitiveness in industry.