Energy Efficiency Revolution: 1MW Solar/Storage/Diesel Hybrid System Powers Plastic Factory in Bamako

⚡Project Overview

A 1MW solar + 1MWh storage + diesel backup system ensures stable, long-term power for a plastic factory in Africa, addressing grid instability.

⚡Customer Background

The factory operates three high-power injection molding machines (120–150kW each), requiring constant, uninterrupted electricity.

⚡Key Challenges

●High power consumption
●Diesel is costly and noisy

●Required 12+ hours of off-grid full-load operation

●Zero tolerance for power outages

⚡Tailored Storage Solution

A modular 1MWh battery system (100kW/215kWh units) offers flexibility, scalability, and redundancy for continuous high-demand operations.

⚡Smart EMS Integration

The Energy Management System (EMS) prioritizes real-time solar use, stores excess power, and activates diesel only when needed—maximizing efficiency and minimizing cost.

⚡Diesel as Backup

Diesel generation acts as a safety net, used only during low solar production or extended night operations, ensuring uninterrupted power.

⚡PV & Load Matching

Rooftop solar provides sufficient daytime energy, reducing reliance on fossil fuels and lowering long-term operational costs.

⚡PCS & AC Coupling

The Power Conversion System (PCS) converts DC battery output to AC, enabling smooth energy flow and smart source switching.

⚡Real-World Application

The hybrid system is built to meet injection machine demands—no shutdowns, no overheating, just stable, continuous power.

⚡Implementation Strategy

• Load assessment
• Customized system design
• On-site installation and integration
• EMS configuration and optimization

⚡Outcomes

●Zero production downtime during outages
●Over 12 hours of reliable off-grid operation
●More than 40% diesel consumption reduction
●Lower OPEX and faster ROI

⚡Broader Impact

This model is scalable for other sectors—remote industries, manufacturing, rural healthcare—unlocking energy independence across Africa.

✅ Conclusion

The Bamako 1MW solar/storage/diesel system proves that hybrid power solutions can deliver reliability, scalability, and sustainability for energy-intensive industries.

❓ FAQs

1. What is BESS?
A Battery Energy Storage System that stores solar power and supplies it when needed.

2. Why include a diesel generator?
It ensures backup power when solar and batteries are insufficient, maintaining production continuity.

3. What does the EMS do?
The EMS intelligently manages energy flow for optimal efficiency, cost savings, and reliability.

4. Can the system be expanded later?
Yes—just add more 100kW/215kWh modules for easy scalability.