Energy security and business continuity despite grid constraints
Grid congestion was preventing the expansion of Esro's production facility in Nuenen. For a manufacturing business operating around the clock, downtime was simply not an option. A flexible, future-ready energy solution was essential to support continued growth.
Grid congestion occurs when the electricity network in a particular region lacks sufficient capacity to meet increasing demand. As a result, Esro's contracted grid connection could no longer support the planned expansion of its production facility.
As a leading company in the food manufacturing sector, Esro processes raw ingredients into products that reach consumers every day. Business continuity and operational reliability are therefore critical.
Esro required a complete solution: an energy system capable of delivering sufficient capacity, providing operational flexibility and supporting future growth.
Following the expansion, electricity demand would exceed the capacity available through the existing grid connection. Upgrading the utility connection within the required timeframe was not a realistic option. Without an alternative solution, the expansion project would have stalled.
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Starting with what was already available
Rather than focusing on limitations, we started with the available assets: a constrained grid connection and a rooftop solar installation.
From there, we mapped the site's complete energy profile, including:
- Baseload consumption
- Peak demand
- Solar PV generation
- Production processes
- Future energy requirements
Based on this analysis, we determined precisely how much power and energy capacity would be required after the facility expansion.
One integrated energy system
Esro now operates an integrated energy system in which all energy assets work seamlessly together.
The entire installation is monitored, controlled and optimised through a central Energy Management System (EMS) and Power Management System (PMS).
Solar PV for renewable energy generation
Battery storage for flexibility and peak management
Stage V generator with AdBlue exhaust after-treatment for peak demand support
The result
By combining renewable generation, battery storage and backup power into one integrated solution, Esro now benefits from a reliable energy supply regardless of grid limitations.
What did we achieve?
- Sufficient power capacity to support the expanded production facility
- No operational impact from grid congestion
- Full visibility and control of the site's energy infrastructure through an intelligent energy management platform
From grid constraints to complete energy control
"Thanks to Zwart's solution, we can expand our production facility without worrying about power availability. Everything works seamlessly together, and we now have complete control over our energy consumption."
Esro Food Group
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In addition to this project, we produced a video together with Esro discussing the challenges they faced, the technical solution that was implemented and the collaboration behind the project.
The video provides a behind-the-scenes look at how complex energy challenges can be transformed into practical, future-proof solutions.
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