JSE-listed cable manufacturer South Ocean Electric Wire (SOEW) has completed a solar installation at one of its facilities that can seamlessly switch from grid to backup power instantly.

The installation, completed at SOEW’s Alrode facility, leverages advanced AI-driven inverter technology and a custom-designed battery storage system to provide uninterrupted power for critical manufacturing processes.

The zero-second switch eliminates downtime, which had previously cost SOEW an estimated R2-million a year owing to loadshedding interruptions.

By maintaining continuous power to production lines, the system safeguards product quality and delivery schedules, which are critical for SOEW’s clients in construction and infrastructure, says SOEW COO Tertius Ness.

“The system optimises energy use based on time-of-use tariffs, weather patterns and kVA demand changes,” he notes.

The system’s effectiveness lies in its hybrid inverter, which synchronises grid and battery power, thereby enabling an instantaneous transition without the typical 10- to 20-second delay seen in conventional setups, he explains.

The solution was developed in partnership with renewable-energy supplier GreenSun and enhances SOEW’s operational resilience.

Additionally, the installation reduces energy costs by 30%, and leverages solar power during peak sunlight hours and stores excess for night-time use. This translates to yearly savings of about R1.5-million.

Environmentally, the shift cuts CO₂ emissions by 600 t/y, thereby reinforcing SOEW’s commitment to carbon neutrality by 2030, Ness adds.

Further, GreenSun’s engineers customised the configuration to handle SOEW’s peak load of 450 kW, thereby ensuring scalability for future expansion. The installation also includes real-time monitoring, which allows SOEW to optimise energy use and respond proactively to grid instability.

This data-driven approach has already improved energy efficiency by 15% since commissioning in June, says Ness.

GreenSun’s solution integrates with SOEW’s specific energy needs, supporting a 500 kW solar array and 1 MWh battery storage.

“The solution not only meets our immediate energy challenges but also aligns with our long-term sustainability goals,” he says.

“SOEW, which is known for producing high-quality electrical cables for local and export markets, has now set a precedent for industrial energy resilience. The sustainable industrial energy installation sets a benchmark for the global manufacturing sector.

“The installation not only secures our operations but also offers a replicable model for other manufacturers facing similar challenges,” says Ness.