How MetSolar delivered R6 million annual savings for South African manufacturer
South African businesses are facing unprecedented challenges with power reliability and rising electricity costs.
For specialist manufacturer Pilot Tools, frequent outages, cable theft incidents, poor power quality, and sky-high diesel consumption were threatening its sensitive production processes.
“The facility needed a solution that would provide clean, stable power while dramatically reducing operational costs,” explained MetSolar’s project team.
The answer was a sophisticated hybrid system that would integrate solar PV, energy storage, and existing diesel generation into one seamless solution.
Solution
MetSolar engineered a comprehensive 412kWp solar installation featuring 756 high-efficiency Jinko Solar panels.
It coupled these panels with a significant 1,000kWh energy storage system using advanced LiFePO₄ battery technology from FreedomWon, as well as high-quality Atess battery inverters, Huawei grid-tied inverters, and DC solar chargers.
The system also included 14 Winline AC to DC rectifiers totalling 560kW, which streamlined the process of transforming grid energy into clean, usable power with zero switching time.
This clean power delivery proved crucial for Pilot Tools’ sensitive manufacturing processes.
The project wasn’t without its challenges, however, including:
- Supply Chain Issues – Delays in equipment supply impacted the project timeline.
- Engineering Challenges – Complex rigging and installation processes due to space constraints.
- Communication Issues – Initial compatibility problems between AC-coupled grid-tied inverters and the EMS.
- Power Quality Issues – Harmonic distortions affected sensitive machinery, leading to potential operational disruptions.
Despite all of these challenges, MetSolar was able to deliver a world-class hybrid energy system to Pilot Tools.
Impressive results
The numbers speak for themselves.
Pilot Tools now saves between R5-6 million annually on electricity costs alone – excluding additional savings from improved production reliability and reduced fuel costs.
With an estimated payback period of just 2-3 years, the project qualified for South Africa’s Section 12B accelerated depreciation allowance, further improving the financial return.
Beyond the financial benefits, the facility now operates with unprecedented power reliability – all while achieving approximately 677,342 tons of annual CO₂ offset.
Solve your energy challenges
MetSolar’s success with Pilot Tools demonstrates that every South African business can take control of its energy requirements.
The company’s approach involves understanding each client’s unique power consumption patterns and designing systems that address specific operational challenges.
From initial engineering through to commissioning, MetSolar provides turnkey solutions that deliver measurable results.
The Pilot Tools project showcases how professional engineering and quality components can transform a business’s energy landscape.
Contact MetSolar today to learn how it can help you solve your energy challenges.
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