Renewable energies need a solid base
Photovoltaic mounting systems from Energy5 are the key to sustainable solar panel substructures thanks to high quality corrosion-protected MagiZinc steel from Tata Steel
- One of Poland’s leading manufacturers of photovoltaic systems for solar farms and roof constructions
- Specialised in innovative & individual photovoltaic solutions, both microsystems and large photovoltaic power plants
- Highly developed research & development activities
- Over 600 customers in Poland and other European Countries
Energy5 relies heavily on research before and during the implementation process, including site surveys and extensive product research. This enables the company to offer customized solutions and thereby differentiate itself in the market. Access to the highest quality materials, the desire to secure the supply chain at the right level and the ability to establish alternative sources of steel are key issues for Energy5's manufacturing operations. Additionally, ZM (zinc-magnesium-based) steel is a key selling point, as steel quality and long-term corrosion resistance has become a critical issue for their customers. As a result, Energy 5 needed a new steel supplier with whom they could not only rely on excellent product quality and service, including participation in testing, but also build a secure, long-term partnership.
"The material supplied by Tata Steel meets the requirements of the photovoltaic industry. At the same time, we are very pleased with the excellent communication. We believe that by investing in MagiZinc steel we are investing in the future and the longevity of our products. "
Cezary Rutkowski, Technical Director Energy5
The high-quality standard that Energy5 follows throughout the whole production process must result in equally high-quality products for their customer portfolio. The raw steel supplied by Tata Steel was therefore extensively tested and analyzed before being incorporated into the production process. Energy5 was quickly convinced that MagiZinc was a strong alternative and a reliable enhancement to the other ZM materials used by Energy5. Tata Steel's quality, availability and flexible approach is highly valued.
MagiZinc is a superior corrosion resistant steel metallic coating that is highly recommended for the manufacturing of cold formed steel profiles for solar panel supports. The advantages of MagiZinc are:
- Excellent formability and weldability
- Extended end product life, reducing maintenance and/or replacement costs
- Reduced production time and cost by eliminating off-site batch galvanising
- Ability to produce complex shaped components with ease and thereby saving assembly time and providing the ability to downgauge.
- Reduced environmental impact through extended product life and reduced raw material consumption
“The most important aspect for us is the quality of the products; we have carried out our own research at an independent institute for approval. Geographical proximity also influenced our decision. There are logistical advantages to choosing a supplier close to the production site. Many other factors came into play, such as a good reputation in the market for a different product range, the technical support offered and very good customer service, not to mention a readiness to engage in negotiations and a commitment to a long-term relationship.”
The benefits achieved through cooperation with Tata Steel are that Energy5 has another reliable partner and together they can work in the renewable energy sector. The measurable effect is the farms built by their customers, their level of satisfaction and the full occupancy of the production facilities. The cooperation has been developing steadily since around 2020. Energy5 is looking forward to Tata Steel developing their product offering in line with market requirements to deliver the next solution with the MagiZinc product.
Tata Steel ensured seamless delivery of the data required for product testing, the results of which played a key role in convincing potential Energy5 customers. Their ability to achieve process stability despite challenges along the way, and to provide flexibility in delivery schedules, exceeded expectations.
Their unwavering commitment to customer focus and exceptional problem solving has enhanced the efficiency and productivity of the implementation phase. Energy5 appreciates Tata Steel's ongoing commitment to service excellence and looks forward to continued success together.
The market has experienced rapid growth, notably in the affordability of solar panels, which were previously deemed expensive until 2010. Ongoing technological advancements continue to drive down the cost of photovoltaics annually. Over the last 50 years, the cost of producing one watt of energy has significantly decreased, dropping from $50 to nearly 30 cents.
Amidst intense price competition within the market, corrosion testing and warranties have emerged as crucial factors in the decision-making process. The potential costs associated with steel element corrosion after 5-6 years present a significant consideration. Simultaneously, warranties enhance the attractiveness of installations to potential investors and buyers.
While implementation challenges are a part of the process which the sides can cooperate on, the response of the market and relevant consumers may vary. Key to navigating these challenges is monitoring products made from the new material and obtaining customer feedback. The collaborative atmosphere with Tata Steel fosters trust and openness, contributing to the establishment of long-term relationships and the discovery of effective solutions.
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BERGERecotrail
Using Ympress® S700MC to manufacture BERGERecotrail® semi-trailer bodies and welded-frames for the chassis delivers a number of benefits, including:
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- Average journey numbers reduced by seven per cent
- A marked reduction in fuel consumption on journeys with lower loads
- Overall cost savings of 6.1 per cent on average
Versatility of fine-grained steel delivers major benefits
Tata Steel also handles the entire management of the supply chain for the production and delivery of a number of different gauges of Ympress S700MC. Our Tata Steel service centre in Germany – manages:
- Production of the Ympress S700MC coils and decoiling
- Needs-based stock holding and transport logistics
- Just-in-time delivery
- Transport of completed parts to the customer’s trailer production plant in Austria
Development of payload-optimisation pays dividends
One particular highlight in the design of the payload-optimised semi-trailer is the two longitudinal beams. The 13.6-metre long components are designed to be very slender and feature cut-outs in the shape of Reuleaux triangles for further weight savings, combined with a high degree of stiffness.
The laser cutting of the webbing is handled by a qualified supplier. Tata Steel functions as an intermediary between BERGERecotrail and the laser facility to ensure the material is completely satisfactory.