How can industrial companies use energy in a truly smart way? Energy systems are becoming more decentralized and flexible—at the same time, the demands on planning, operation, and economic efficiency are increasing.
At the Green Factory Ungerhausen, forecast-based schedule management is already being used as a strategic lever for efficiency, climate protection, and cost optimization.
From reacting to thinking ahead—why this is a game changer for business
Many businesses now operate rooftop PV systems, CHP units, and boiler systems. With the transformation of the energy center, favorable conditions for electrification and energy storage such as battery storage, electric boilers (electric heating elements), heat pumps, or charging infrastructure, classic load management systems (LMS) are reaching their limits. LMS usually work with rigid threshold values and only react when limit values are reached.
In short: they extinguish fires instead of preventing them.
Forecast-based schedule management (FlexA) goes one step further and makes the energy system proactive:
- Digital twin of the energy system with static plant data, technical restrictions, and price parameters
- Automated data flow: measured values, weather data, and resulting load/heat/PV forecasts and dynamic electricity prices
- Optimization in terms of costs, CO₂, peak loads, and self-sufficiency – while complying with technical constraints
- Schedule generation for resource planning with manual or automated execution via the local LMS with fallback control on the LMS for situational rules
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Added value for the business: Decisions are made proactively, operating modes are predictable and robust—rather than ad hoc and reactive.
This is how things work at the Green Factory in Ungerhausen
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In Ungerhausen, a diverse range of systems is integrated into cloud-based schedule management: PV roof system (~2.2 MWp), CHP (~220 kW el./250 kW th.), peak load boiler, wood pellet boiler, electric heating elements (600 kW el.), two battery storage systems (1,500 kWh / 160 kWh), and charging infrastructure.
A local controller connects read (actual values) and write (target values) data points from multiple PLC/LMS and EMS systems and links the LMS to cloud-based schedule management.
After a short training phase, reliable forecasts were available; based on these, schedules for the CHP unit and the large battery storage system were generated and executed via the LMS. Other flexible systems (including heat pumps and charging station groups) are being integrated step by step. Situational control interventions remain active as a fallback solution.
Result: Lower emissions, reduced costs – greater predictability
Simulations and initial operating experience in the Green Factory show clear effects:
- Up to 50% lower electricity and heat supply costs
- Annual peak load reduced by around one third
- Approximately 30% lower COâ‚‚ emissions
- 15 percentage points higher degree of self-sufficiency
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Important for classification:
These effects arise from the interaction of forecast-based schedule management (FlexA) with appropriate system technology and operating strategy—specifically through
(1) Peak load management via schedule and storage,
(2) greater use of own electricity generation,
(3) Integration of additional flexibilities such as large heat pumps and charging infrastructure,
(4) Prospect of dynamic electricity tariffs.
Without these framework conditions, FlexA alone cannot be expected to reduce costs by 50% across the board; however, the expansion of battery storage and heat pump systems increases the complexity of the LMS, but at the same time creates flexibility.
Link to the article (external): https://zenodo.org/records/182303
Why FlexA raises the potential – and why an LMS alone has its limitations
Classic LMS with rigid rules are ideal for simple shutdown cascades (peak load avoidance), but reach their limits when dealing with heterogeneous plant fleets and multiple target values. Classic LMS are not being replaced; they are an important basis and, in combination with FlexA, enable complex energy systems to be controlled in an optimized manner.
FlexA makes the difference here:
- Forward thinking instead of reaction: forecasts + optimization instead of ad hoc threshold logic
- Holistic goal management: costs, peak loads, COâ‚‚, and self-sufficiency in one schedule
- Operational robustness: Fallback to situational rules in case of forecast deviations or cloud failure
- Operational relief: Fewer manual interventions in the control room, standardized operating modes, fewer operating errors; malfunctions caused by inappropriate switching sequences can be prevented
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In short: without FlexA, the potential of existing flexibilities (own consumption, peak loads, CO₂) remains untapped. With FlexA, it is systematically leveraged—with less internal effort and greater operational reliability.
Looking ahead: The basis for flexible rates and more
Forecast-based schedule management is not just an optimization tool for today: it creates the conditions for future applications—above all, dynamic electricity tariffs, which must be offered on a mandatory basis from 2025 onwards.
With each additional flexible system connected (e.g., heat pumps, charging stations, electric boilers), the degree of freedom increases—and with it, the economic and ecological potential.
More background information and details in ew – Magazine for the Energy Industry. Click here for the article:
https://zenodo.org/records/18230397
With e-con AG: https://econ-ag.com/Â
and Alois Müller: https://alois-mueller.com/