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A Commercial & Industrial ESS Project by KOODSUN
Category: Industrial Solar & Energy Storage Project
Location: Ukraine
Application: Mechanical Processing Factory
As industrial electricity costs rise and power supply reliability becomes increasingly important, manufacturers are looking for ways to improve energy independence while maintaining stable production.
KOODSUN recently completed a solar-plus-storage project for a mechanical processing factory in Ukraine, combining a 180kWp solar PV system, two 60kW hybrid inverters, and 482kWh of LiFePO₄ battery storage.
The project uses two 241kWh air-cooled outdoor ESS cabinets to store surplus solar energy and make it available when solar generation is insufficient or additional power support is required.
The system was designed around the factory's industrial electricity requirements, with three main objectives:
Increase on-site solar energy utilization.
Reduce dependence on grid electricity through battery energy storage.
Provide additional power supply support during grid interruptions.
Rather than installing solar panels alone, this project combines solar generation, hybrid power conversion and battery storage into an integrated energy solution.
| Component | System Configuration |
|---|---|
| Project Location | Ukraine |
| Application | Mechanical Processing Factory |
| Solar PV Capacity | 180kWp |
| Hybrid Inverters | 2 × 60kW |
| Total Inverter Capacity | 120kW |
| Battery Storage | 2 × 241kWh |
| Total Battery Capacity | 482kWh |
| Battery Chemistry | LiFePO₄ |
| ESS Cabinet Type | Outdoor Air-Cooled |
| Cabinet Protection | IP54 |
| Operating Temperature | -20°C to +45°C |
| Nominal DC/AC Ratio | 1.5 |
| Commissioning | Q3 2026 |
The battery system provides 482kWh of nominal energy storage. At a 90% depth of discharge (DoD), the theoretical available energy is approximately 434kWh, subject to the battery's operating limits and system settings.
The project consists of three main components: solar PV generation, hybrid inverter conversion and lithium battery storage.
The 180kWp solar array serves as the primary renewable energy source for the factory.
During daylight hours, solar electricity can support the factory's operating loads. Depending on the actual production schedule and energy management settings, surplus solar generation can also be used to charge the battery system.
The 180kWp PV capacity compared with the combined 120kW inverter rated power gives a nominal DC/AC ratio of 1.5.
This configuration is intended to balance solar energy generation with inverter capacity and battery charging requirements.
Actual PV input allocation and power clipping depend on the selected inverter's maximum PV input specifications, MPPT configuration and operating conditions.
The system uses two 60kW hybrid inverters, providing 120kW of combined rated AC power.
The hybrid inverters coordinate the energy flow between the solar PV system, battery storage, factory loads and utility grid, according to the system configuration.
Their main functions include:
Converting solar DC electricity into AC electricity for factory consumption.
Managing battery charging from available solar energy.
Discharging stored battery energy when required.
Coordinating grid interaction and configured backup operation.
Using two inverter units also provides a modular system configuration, allowing the project to be arranged around the site's power distribution and installation requirements.
For industrial applications, inverter selection must consider not only rated power but also motor starting current, overload capability, three-phase requirements and backup operating characteristics.
The battery system consists of two KOODSUN 241kWh air-cooled outdoor ESS cabinets.
<Insert product image: KOODSUN 241kWh Air-Cooled Outdoor ESS Cabinet>
Together, the two cabinets provide 482kWh of nominal energy storage.
Key product features include:
LiFePO₄ battery chemistry.
Integrated Battery Management System (BMS).
Air-cooled thermal management.
Outdoor cabinet design.
IP54 enclosure protection.
Designed operating ambient temperature range of -20°C to +45°C.
The air-cooled design offers a practical solution for industrial customers who need outdoor battery deployment without the additional liquid-cooling circulation system.
Each cabinet integrates battery modules and the associated battery protection and management components, simplifying the installation of modular storage capacity.
The main purpose of this project is to improve the factory's energy utilization by combining solar generation with battery storage.
The system can operate through several energy management strategies, depending on grid availability, solar production and factory demand.
Mode 1: Daytime Solar Power Supply
During the day, solar electricity is used to supply the factory's operating loads.
When solar generation exceeds immediate consumption and the battery has available charging capacity, surplus energy can be stored in the ESS.
Mode 2: Battery Discharging
When solar production decreases, the battery can discharge to support factory electricity consumption.
This allows the factory to make better use of energy generated earlier in the day rather than relying entirely on grid electricity.
Mode 3: Peak Shaving and Time-of-Use Optimization
The battery can be scheduled to discharge during selected periods of higher electricity demand or higher electricity tariffs.
When the local tariff structure supports this strategy, the system can help reduce grid electricity consumption during targeted periods.
The actual economic benefits depend on the factory's load profile, electricity tariff, battery operating strategy and round-trip efficiency.
Mode 4: Backup Power
During grid interruptions, the hybrid inverter and ESS can provide backup power to designated factory loads, subject to the inverter's backup configuration and available battery energy.
For industrial facilities, the backup design must account for maximum demand, motor starting currents, load priority and the required backup duration.
Mechanical processing factories have different electricity requirements from ordinary residential or commercial buildings.
Their electricity consumption can vary significantly depending on production schedules and the equipment operating at any given time.
Several factors are particularly important when designing an industrial solar-plus-storage system.
Manufacturing equipment may include CNC machines, cutting machines, compressors, pumps and other electrically driven machinery.
These loads can change throughout the production day.
Therefore, system sizing should consider both average energy consumption (kWh) and maximum instantaneous power demand (kW).
Some industrial motors require substantially higher current during startup than during normal operation.
A suitable hybrid inverter must therefore be selected based on its overload characteristics and compatibility with the factory's motor loads.
For factories with suitable electricity tariff structures, combining solar generation and battery storage creates opportunities for self-consumption optimization and peak shaving.
Instead of consuming all electricity directly from the grid, the factory can use solar generation and stored energy as additional electricity sources.
Grid interruptions can affect manufacturing schedules and production continuity.
An appropriately configured ESS can provide backup power for selected equipment and critical production processes.
The actual backup duration depends on the supported load and usable battery energy.
For commercial and industrial projects, outdoor ESS cabinets offer several practical advantages.
Modular Configuration
The use of two independent 241kWh cabinet units provides a total of 482kWh of nominal storage capacity.
This modular approach offers flexibility in equipment placement and system installation.
Integrated Battery Management
The integrated BMS monitors battery operating conditions and manages battery protection.
Outdoor Installation
The IP54 outdoor enclosure is designed for installation in appropriate outdoor environments, subject to site preparation and installation requirements.
Air-Cooled Thermal Management
Air cooling avoids the liquid circulation and coolant maintenance requirements associated with liquid-cooled systems.
For projects in colder climates, the battery's actual low-temperature charging and discharging limits, as well as any heating requirements, must also be considered during system design.
Every factory has a different electricity consumption pattern. Therefore, simply selecting a large PV array or battery capacity does not guarantee the best project economics.
Before recommending a complete solution, KOODSUN evaluates several important factors:
Daily electricity consumption: How many kWh does the factory consume per day?
Maximum power demand: What is the highest simultaneous electrical load?
Production schedule: Does the factory operate during the day, at night or continuously?
Grid conditions: Is the system grid-connected, backup-oriented or designed for off-grid operation?
Backup requirements: How many hours of backup power are required, and which loads must remain operational?
Solar installation conditions: How much PV capacity can the available rooftop or ground area accommodate?
Battery requirements: What storage capacity and discharge power are necessary?
These factors help determine the appropriate combination of solar panels, hybrid inverters and battery storage.
The Ukraine project demonstrates how a 180kWp solar array and 482kWh ESS can be combined into an industrial energy solution.
However, the optimal configuration for another factory must always be determined by its actual electricity consumption and operating requirements.
Q1: What is the total battery capacity of this Ukraine project?
The system uses two 241kWh outdoor ESS cabinets, providing 482kWh of total nominal battery capacity.
Q2: How much usable energy can a 482kWh battery system provide?
At 90% DoD, the theoretical usable energy is approximately 434kWh. Actual available energy depends on BMS limits, operating conditions and system configuration.
Q3: Why does the project use 180kWp solar PV with 120kW of hybrid inverters?
The nominal DC/AC ratio is 1.5. This design provides a larger PV generation capacity relative to the inverter's rated AC output. The final configuration must also comply with the inverter's maximum PV input and MPPT specifications.
Q4: Can an industrial ESS operate during a grid outage?
Yes, if the selected hybrid inverter supports the required islanding and backup functions and the system is configured accordingly. The supported load and backup duration must be verified during engineering design.
Q5: Can KOODSUN customize an ESS solution for other industrial applications?
Yes. KOODSUN provides customized battery storage solutions for manufacturing facilities, warehouses, agricultural projects, cold storage facilities and other commercial and industrial applications.
Solutions can be configured according to the required inverter power, battery capacity, PV generation capacity and site operating conditions.
Anhui KOODSUN Technology Co., Ltd. is a manufacturer specializing in lithium battery products and commercial and industrial ESS solutions.
Our product portfolio includes:
Residential LiFePO₄ batteries.
Low-voltage and high-voltage battery systems.
Air-cooled outdoor ESS cabinets.
Liquid-cooled outdoor ESS cabinets.
Containerized BESS.
Customized solar-plus-storage solutions.
KOODSUN works with international distributors, EPC contractors, project developers and industrial customers to provide battery storage products and integrated energy solutions.
From residential backup systems to large-scale industrial energy storage projects, our engineering team supports customers in selecting suitable battery capacity, inverter power and system configurations.
Planning an Industrial Solar + ESS Project?
If you are planning a solar and battery storage project for a factory, warehouse, agricultural facility or other industrial application, KOODSUN can help evaluate your requirements and develop a suitable solution.
Send us the following information to receive an initial system recommendation:
Project location and application.
Daily electricity consumption (kWh).
Maximum power demand (kW).
Available solar PV capacity or installation area.
Required battery backup duration.
Grid voltage and phase.
Contact KOODSUN to discuss your next commercial and industrial ESS project.
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