Schaltbau, a global leader in direct current (DC) technology, has received the FREDDIE AI Industrial Award in the “Sustainability” category for the AI-based energy management system at the NExT Factory, the world’s first DC factory in Velden, Germany. The award recognizes how the system intelligently connects a wide range of energy sources, consumers, and storage systems, setting new benchmarks in industrial energy supply performance and sustainability.

“AI, sustainability and economic impact go hand in hand. Because no suitable energy management system for DC fed industrial power supplies existed, we developed one ourselves, just as we did when creating the world’s first DC factory,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “This double pioneering spirit defines who we are: when solutions don’t exist, we create them. And then we share them. Our NExT Factory and its AI-driven EMS form a blueprint for the All Electric Society, helping drive the global transition toward smarter, cleaner, and more resilient industrial power systems.”

The idea for an AI-driven energy management originated during Schaltbau’s pioneering project to build the world’s first DC factory. With no existing solution available, the company built its own, extending its innovation from factory concept to the intelligent systems that power it. By directly coupling energy generation from a rooftop photovoltaic system, storage, and consumption on a DC microgrid, conversion losses are minimized, significantly increasing overall system efficiency and reducing costs. Managing such a system, however, is highly complex and cannot be handled with static, rule-based algorithms. Thousands of data points must be processed every second — from power flows and production schedules to weather forecasts, load shifting to sunny periods, and variable electricity tariffs.

The NExT Factory’s EMS, supporting both DC and AC networks, uses artificial intelligence to dynamically learn, recognize patterns, forecast future power consumption, and enable predictive, efficient control of the entire DC energy supply network. The scalable system was developed in-house with a cloud-based backend and a local edge application, and it received funding from the Federal Ministry of Research, Technology and Space under the SynErgie3 project.

The FREDDIE Industrial AI Award, initiated by publish-industry and UnternehmerTUM, recognizes outstanding applications of artificial intelligence in manufacturing and industrial environments. It honors projects that demonstrate how AI can transform industrial processes, enhance efficiency, and deliver measurable value. Award-winning solutions typically stand out for their technical excellence, industrial relevance, scalability, degree of innovation, business impact, and future potential. With both factory concept and the in-house AI-based EMS, Schaltbau continues to share insights and best practices with partners and the wider industry – because advancing DC technology is a collective mission toward a more sustainable future.

“When we planned our NExT Factory with a DC microgrid and smart energy management, we wanted to minimize energy losses that happen when direct current is converted into alternate current and vice versa. But we also wanted to minimize the ‘conversion losses’ that happen when teams don’t have the working environment or the fast mutual exchange they need,” said Dr. Michael Ettl, Senior Director Operations, Schaltbau. “We are very honored to receive this award. It shows that the principles of New Work, collaboration and transparency can very well transcend to manufacturing sites.”

The 2.000 m² open office space in the NExT Factory was designed on the basis of both qualitative workshop and quantitative survey data on the working methods and communication relationships of the various teams in the factory. It allows “activity-based working”, namely, provides inviting space for individual work and concentration as well as discussions and creative team meetings. The respective “home zones” of departments in the open space concept were arranged based on the communication relationships between the different teams, facilitating both transparency and smooth collaboration. 

The NExT Factory has been in full operation since September 2023. With its advanced DC components, photovoltaic energy generation, intelligent energy management as well as battery and thermal storage, the NExT Factory saves up to 35% in annual energy costs. As a result, the facility is significantly less reliable on the conventional power grid and sets a new standard for carbon-neutral and electrified production. 

“When we decided to expand our production capacity in 2019, we faced all the challenges manufacturers are being confronted with today,” said Steffen Munz, CEO at Schaltbau. “But we seized it as an opportunity to break new ground. We decided to use our direct-current technology expertise and product portfolio to create the world’s first direct current factory. We are very honored to win the Energy Efficiency Award and hopeful that other companies feel encouraged to explore the economic and environmental benefits DC grids can bring to their production sites.” 

Schaltbau’s NExT Factory represents a pioneering leap in sustainable manufacturing and energy efficiency. Built with the future of energy transition in mind, the NExT Factory leverages the natural advantage of renewable energy sources like solar power to produce direct current. Unlike traditional factories that convert DC into alternating current (AC) for distribution, the NExT Factory maintains a DC-based infrastructure that efficiently delivers electricity generated from its expansive rooftop photovoltaic (PV) system directly into the plant’s operations. This streamlined approach bypasses the energy losses associated with DC-to-AC conversion, resulting in an energy savings of up to 15%. 

In addition, the factory integrates intelligent energy management systems that monitor, optimize, and balance energy use in real-time, further enhancing efficiency. Through this advanced energy management and DC grid approach, the NExT Factory achieves a total reduction in energy consumption and costs of up to 35% annually. This not only reduces the factory’s operational costs but also minimizes its environmental footprint, setting a powerful example for the manufacturing industry’s path toward climate neutrality. 

The Energy Efficiency Award stands for responsibility, innovation and entrepreneurship and has been showcasing concrete successes for the energy transition and climate protection since 2007. It recognizes projects for energy and CO2 savings as well as concepts that demonstrate how the path to climate neutrality and the transformation of industry can succeed.

Learn more in the video below (in German). 

Schaltbau, a global industry leader specializing in direct current (DC) technology, has received the German Award for Sustainability Projects in the “Technology – Energy” category. The company received the award as creators of the world’s first direct current, resource-saving and carbon-neutral factory in Velden, Germany. The manufacturing facility, which has been in full operation since September 2023, can serve as a blueprint for energy-efficient and green supply chains in Europe. 

The German Award for Sustainability Projects recognizes outstanding sustainability endeavors which create social, economic and environmental impact in line with the United Nations’ Sustainable Development Goals. 

“We are very proud to take the German Award for Sustainability Projects home this year,” said Steffen Munz, CEO at Schaltbau. “The NExT Factory is a pioneering showcase for resource-saving and carbon-neutral production. We are passionate about setting new standards in green production for a sustainable future. And we hope to encourage others to follow suit – it is rewarding.” 

The NExT Factory’s DC microgrid is a pioneering technology for effectively integrating renewable energies into production, not least because it eliminates conversion losses and increases energy efficiency. With its advanced DC components, photovoltaic energy generation, an intelligent energy management as well as battery and thermal storage, the NExT Factory functions like a circular economy for energy and saves 35% in annual energy costs. As a result, the facility is significantly less reliable on the conventional power grid and sets a new standard for carbon-neutral and electrified production. 
 

Schaltbau, a global leader in direct current (DC) technology, will showcase innovative Eddicy solutions for energy storage and battery technologies at “The Battery Show Europe,” which will take place in Stuttgart from June 18-20, 2024; and the “ees Europe,” from June 19-21, 2024 in Munich. 

Whether it’s energy storage systems, charging infrastructures, or electromobility, DC technology is more critical now than ever before. A key component in the transition to renewable energy, DC power must be leveraged for efficient and reliable use—and Schaltbau’s line of Eddicy bidirectional contactors make that a possibility. 

Highlights will include the C303 contactor, engineered for bidirectional DC applications and offering unmatched performance suitable for a range of uses in energy storage, charging stations, electric vehicles, and vehicle-to-grid (V2G). With a very low contact resistance of slightly over 100 µΩ, the C303 offers best-in-class performance with low contact warming and low power loss due to optimized contact pills. The coil drive with fast switch on and AgSnO2 contact tips result in superior performance in short time currents (5kA capacity for 20 milliseconds without contact welding) and high making capacity (currents up to 2kA without contact welding). The smallest Schaltbau contactor for 350A Thermal current, the C303 offers complete plug-and-play capability. 

The company will also showcase the new C800 bidirectional contactors for e-mobility applications. With a making capacity of up to 4,500 amperes and continuous current carrying capacity of up to 500 amperes, they are ideal for use in the Battery Disconnect Unit (BDU) of electric vehicles. They can even handle short-circuit currents of up to 6,000 amperes for 20 milliseconds without the contacts welding, maintaining full functionality to switch large currents, such as up to 1,200 amperes at 450 volts, regardless of the current direction. 

Attendees are invited to meet Schaltbau at each event to explore how these bidirectional contactors can enhance energy sustainability and resilience: 

Eddicy at The Battery Show Europe 
Date: June 18-20, 2024, Stuttgart, booth 8F35 

Eddicy at ees Europe 
Date: June 19-21, 2024, Munich, booth B2.381 
 

For more information about each event, please visit us here:  https://www.schaltbau.com/en/news/trade-shows/the-battery-show-ees-europe/ 
 

Schaltbau, a global leader in direct current (DC) technology, has been awarded the prestigious German Innovation Award 2024 with Gold distinction in the “Excellence in Business to Business” category for innovative energy solutions. This esteemed accolade celebrates Schaltbau’s outstanding commitment to innovation and its impact on the future of manufacturing with the NExT Factory, the world’s first DC factory and a pioneering project for an energy-efficient, and carbon-neutral production.

The German Innovation Award recognizes products, projects and pioneering achievements that sustainably improve life through innovation and progress. Each year, nominees are selected for creating added value in society, the environment or the economy through their innovative processes and ideas.

“We are very honored to win the German Innovation Award 2024,” said Steffen Munz, CEO at Schaltbau. “This recognition speaks to our commitment to innovation and our passion to push the boundaries of direct current technology. We are passionate about setting new standards in green production for a better, more sustainable future.”

Schaltbau’s relentless pursuit of excellence and innovation in DC technology has positioned the company as a pioneer of carbon-neutral production, aiding the industrial transition to renewable energy. The NExT Factory has redefined the standard of manufacturing, with advanced smart grid components and intelligent energy management, battery and thermal storage, it sets a new standard for energy-efficient, carbon-neutral and electrified production.