Digitalized energy self-sufficiency at Meduna heat treatment plant
About this good practice
Meduna, a modern metal heat treatment plant in Pardubice, specializes in vacuum quenching furnaces for small-batch processing. The company operates in a highly sensitive industrial segment where even brief power outages can interrupt critical furnace charging cycles, leading to product defects and large financial losses. Rising energy costs and sustainability goals also motivated the company to seek energy independence.
To address these challenges, Meduna adopted a holistic strategy combining renewable energy, battery storage, cooling system upgrades, and digital energy monitoring. A rooftop photovoltaic system (192 kWp) was installed to cover up to 10% of annual electricity needs, with fully on-site consumption. A 220 kWh battery with fast inverters provides backup during micro-outages and performs peak shaving to reduce contracted grid capacity overruns.
Cooling system controls were optimized using regulated circulation pumps that respond dynamically to process needs, reducing electricity consumption significantly. Additionally, the company developed KalNova, a custom digital energy management tool that maps energy use per order and process, enabling real-time optimization and cost tracking.
Main stakeholders include Meduna, its technology partners, and funding bodies (e.g., OP PIK, OP TAK by the Ministry of Industry and Trade). Beneficiaries are the company’s clients, employees, and the environment.
Expert opinion
Resources needed
Total investment ~1.4 mil. EUR: PV plant + battery ~320k EUR, cooling system automation + KalNova software ~1 mil. EUR, electromobility ~78k EUR. Co-funded up to 45% by OP PIK and OP TAK national funds for SME competetiveness. Implementation involved internal technicians and certified contractors.
Evidence of success
Meduna reduced energy costs via on-site solar generation and peak shaving. Battery storage minimized disruptions from micro-outages critical to vacuum heat treatment furnace operations. Cooling upgrades improved thermal stability and cut energy use. The KalNova system enabled real-time energy tracking, enhancing process efficiency and pricing accuracy. The plant now covers ~10% of its annual electricity needs from solar PV.
Potential for learning or transfer
Meduna’s approach is highly relevant for SMEs in energy-intensive sectors, particularly those with process sensitivity to power quality and grid micro-outages. Its modular integration of PV, battery storage, and smart cooling can be replicated with relative ease, especially where national or EU funding is available. The custom KalNova system demonstrates the value of digitalization in energy management.
Key success factors include a clear understanding of process-specific energy needs, smart use of subsidies, and in-house technical expertise. Potential barriers may involve initial investment costs and IT capacity for digital tool development.
The model can be transferred to other NUTS 2 regions with similar industrial profiles where manufacturing SMEs face energy stability and efficiency challenges.
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