How Battery Storage Systems Boost Manufacturing Efficiency

UK manufacturers are under growing pressure from energy volatility and unreliable grid performance. 

In this context Aggreko, a company specialising in energy solutions, points to battery energy storage systems (BESS) and hybrid power setups as viable options to improve both resilience and on-site efficiency.

Energy prices in the UK are among the highest for industrial users across Europe. Compared to Germany or France, UK manufacturers pay around 50% more, and the gap widens when compared with the US, where prices are roughly four times lower. 

The pressure is not only financial but also operational, as power quality and supply issues add to the existing challenges.

Trade association Make UK has responded with a detailed plan in its report ‘Tackling Electricity Prices for Manufacturers’, aimed at addressing the imbalance. 

The report sets out a costed approach to restore sector competitiveness and create the conditions for growth. Without energy reform, Make UK argues, the cost crisis will continue to weigh down the industry.

Hybrid power options for an unstable market

In response to these conditions, Aggreko is using its guide Sharing the Load to explain how temporary hybrid power solutions, particularly those incorporating BESS, could offer short- and medium-term relief. 

According to the company, these setups enable manufacturing businesses to manage energy consumption more dynamically.

Steve Ennis, Manufacturing Sector Manager at Aggreko, states: “While both understanding and usage of battery storage remains in relative infancy in this sector, there is significant potential for this technology to help address some of the major challenges that UK manufacturing is facing today."

He explains that, if correctly implemented, BESS allows production sites to shift power usage in response to changing electricity prices or production cycles. 

This flexibility could offer manufacturers a tactical edge, making operations more adaptable to market conditions.

Steve continues: “The aim of our latest guide is to facilitate this by highlighting just some of the real-world applications for battery storage in manufacturing.”

Storing low-cost energy for high-demand periods

One application covered in ‘Sharing the Load’ involves charging BESS during periods of low power demand, then using that stored electricity during peak times. 

This method is particularly effective when paired with hybrid systems in settings with transient loads – temporary spikes in power usage that occur when machinery like electric motors are powered on.

In these instances, BESS can manage the initial power surge. This means the generator used for the steady base load can be smaller and operate more efficiently. The outcome is improved overall energy use, better cost control and reduced strain on local grid infrastructure.

In addition to outlining practical uses, Sharing the Load addresses a number of false assumptions about BESS. It also includes examples from Aggreko’s own site tests, showing how hybrid systems perform under real-world industrial conditions.

Making the case for outsourced storage systems

Steve says Aggreko understands the manufacturing sector’s focus on predictability and margins. Any capital investment comes with risk, especially when returns are not immediately clear. This, he argues, is where outsourced battery storage solutions offer an advantage.

Rather than making a large up-front investment in equipment and integration, manufacturers can bring in battery technology from a third-party specialist. 

This model allows them to test and measure BESS performance in their own environment without taking on asset risk.

Steve concludes: “We understand that manufacturing is a business that relies upon certainty. With such tight margins, every investment feels like a risk unless manufacturers can guarantee that it will generate returns for their business.

“This is where outsourcing battery technology from a specialist can come into play, allowing manufacturers to integrate the technology into their set-up in a risk-free manner, and see what it can really do for their plant.

“I would encourage everyone in the sector to read our latest guide – you might just be surprised what BESS are capable of.”