Case Studies

The right hybrid power systems can reduce expenses and improve environmental standings, but only if done right.

The implementation of a BESS at the Century Yuasa factory represents a major step forward in industrial efficiency. By deploying advanced energy storage solutions, the facility can now manage peak demand and stabilise power quality, ensuring that the high-precision battery manufacturing process remains uninterrupted.

CYB FACTORY BESS

Century Yuasa Batteries (CYB) are expanding our DC Power system capabilities into the industrial Battery Energy Storage market (BESS). To demonstrate our competancy in this field, where else would be better to trial this technology than here at the head office and factory in Queensland.

Integrating a large-scale lithium BESS into an active manufacturing environment required a comprehensive suite of Industrial Power System Services. From the initial site audit to the complex electrical engineering required for grid synchronisation, our team ensured the system was balanced for both performance and safety.

The initial goal is to develop and install a working BESS system at the CYB factory. This will be a live and operational system designed to;

• reduce the peak factory energy consumption profile and hence reduce our electricity bill. It will also be used as a demonstration system for potential standby customers.
• provide interfaces allowing local and remote display of energy consumption and related savings (such as large screen local LCD display and potential web interface allowing customers to log on and see a system in action). This will be a valuable sales tool for these systems.
• provide a test bed for Engineering to evaluate and develop system architectures, software controls and interfaces for future research and development activities.

The system architecture includes the following components:

• 110 kVA Bi-Directional Inverter
• 115 kVA Coupling Transformer
• Initially configured with a 76 kWHr Battery Bank (3 Strings), to be replaced later with a 360 kWHr Cyclic Battery to test our Advanced VRLA battery products
• 1000 VDC Distribution Board
• Proprietary Battery Management System
• Interconnection Protection Relay

For an asset as critical as a factory BESS, the installation is only the beginning. Ongoing Power System Maintenance and Support is essential to monitor cell health, thermal management systems, and inverter efficiency, ensuring the system continues to deliver a strong return on investment throughout 2026 and beyond.