The challenge
The client operates a 24/7 ambient distribution shed with 15 electric forklifts charging in three staggered shifts. The challenge was to maximise self-consumption on a building where demand runs continuously — including overnight when solar is not generating — while integrating the forklift charging bank with the solar generation curve to avoid grid import during the day. The existing half-hourly metered tariff also carried demand charges that a mismanaged battery installation could inadvertently worsen.
Our solution
FLD modelled 12 months of half-hourly consumption data alongside the PVGIS generation profile for NP20. The SolarEdge energy management system was configured to prioritise forklift charging during the 09:00 to 15:00 peak generation window, diverting surplus generation to the 20-point 22 kW forklift charging bank before exporting to grid. A 250 kWh BESS was added to capture afternoon surplus for the evening demand peak, with the SolarEdge demand setpoint controller set to prevent demand peaks above 350 kW. NGED G99 Type A approval was obtained in 13 weeks.
The result
Year-one generation 387,000 kWh against 380,000 kWh modelled. Self-consumption 84% against 78% modelled — the forklift charging integration performed above expectation. Annual demand charge saving from BESS: £16,400. Total year-one benefit: £119,400 against £103,000 modelled. Ynni Cymru grant of £50,000 secured, reducing net capex to £290,000 and post-grant AIA payback to 1.9 years.
The forklift charging integration was the differentiator. Our previous quotes just gave us a panel count. FLD modelled the half-hourly consumption, designed the demand management correctly and the results have exceeded the model.
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