Setting new standards in energy supply together with local partners
The new photovoltaic system covers the 10,000 square meter roof area of Plant 3 at the company’s Kassel-Waldau location. With a module output of 1.1 megawatt peak (MWp), it sets new standards for energy-efficient power production. The system was realized in cooperation with the local municipal power company Städtische Werke Kassel using high-performance inverters from the Kassel-based company SMA Solar.
“Sustainability is something that is simply part of our company’s DNA and we are firmly rooted in Kassel with our headquarters,” emphasizes Ingolf Cedra, Managing Director of the HÜBNER Group. “That's why it is important to us to make investments in our energy supply – as with this new photovoltaic system – in conjunction with local partners such as the power company Kassel Städtische Werke and SMA Solar for the system’s inverters.”
One of Kassel’s largest PV systems: CO2 emissions reduced by 733 tons
Year by year, the new photovoltaic system will generate 1,049 megawatt hours (MWh) of electricity. Approximately two thirds of this amount will be used directly at the facility, making Plant 3 more independent from external energy supplies. The surplus electricity of around 380 MWh per year will be fed into the public grid. This yields a reduction of approximately 733 tons of carbon dioxide (CO2) emissions per year.
“We are delighted to have built one of the largest photovoltaic plants in the city of Kassel – with a peak output of 1.1 MW – for our partner HÜBNER,” says Städtische-Werke Chief Executive Officer Carsten Harkner.“Integrating a system of this size into an existing distribution grid is a challenge, even if the majority of the energy generated is used locally by HÜBNER. But we are happy to take on this challenge, because it brings us a big step forward in the energy transition and secure energy supply.”
New plant roof with improved insulation
In Plant 3, the Material Solutions division mainly manufactures products and components made of elastomers and polyurethane. The Plant 3 production features a high degree of automation with substantial use of self-generated electric power – ideal conditions for a particularly efficient application of a photovoltaic system.
HÜBNER has also established better conditions for increased energy efficiency in connection with the solar project. “Through energy-efficient renovation, we have not only improved the insulation and reduced the long-term need for thermal energy but have also prepared the plant roof for the new photovoltaic system,” explains Timo Eckelsbach, Head of Technology, Central Building and Service Management.
Adding to an existing system at the Kassel site
With the new photovoltaic system, the HÜBNER Group has achieved an output of more than one megawatt, which represents a new order of magnitude in solar power production for the company in Germany. This required a more extensive approval process. Nevertheless, planning and implementation were completed on schedule within nine months.
The production and storage hall at Plant 2 in Kassel – with a roof area of 6,100 square meters – has already had a photovoltaic system for several years. The 1,400 photovoltaic modules in this system generate 338 megawatt hours of electricity annually, most of which is used for the Plant 2’s own consumption.
New PV systems at locations in India, Hungary and Germany
Since 2023, the HÜBNER Group has brought photovoltaic systems into operation at various plant locations around the world. One example is the Namma Factory near the Indian metropolis of Bengaluru, which was launched in April 2023 and now employs around 175 people. In just the first year of operation at this facility, more than 587 megawatt hours (MWh) of electricity were generated from solar energy.
At the end of 2023, a photovoltaic system was also added in Nyíregyháza, Hungary, the second largest location in the HÜBNER Group with around 900 employees. At 1.1 megawatt peak (MWp), it has a similar capacity to the new system in Kassel.
Also in 2023, modules for a new photovoltaic system were installed on a plant roof at the PolymerTechnik Ortrand GmbH (PTO), a HÜBNER Group company located near Dresden. This will make it possible for PTO to cover approximately 400 megawatt hours (MWh) from its own sources with its production of industrial textiles such as coated fabrics for gangway systems. This amounts to roughly eleven percent of its annual requirements.
Progress with energy efficiency
Besides the generation of solar power, numerous measures are being undertaken at HÜBNER locations that contribute to a continuous reduction in energy consumption. These include initiatives to switch from natural gas to district heating as well as the integration of measures to make use of waste heat. HÜBNER has made particular progress in energy reduction with the use of compressed air, one of the most energy intensive production resources in the industrial sector. Over the past ten years, the company has been able to improve its energy efficiency by over 100 percent in this area.
“We have set ourselves the general goal of saving at least four percent of our energy consumption each year,” explains Thomas Meibert, Energy Management Officer at HÜBNER.“By 2040, we want to cover 100 percent of our energy requirements from renewable sources.” To achieve these goals, the company is practicing comprehensive environmental and energy management in accordance with the ISO 50001 certification. In addition, the HÜBNER Group has received the Ecovadis Silver certificate, which recognizes the company’s efforts in connection with environmental, labor and fair business practices, as well as with sustainable procurement.
Increasing sustainability long a part of the HÜBNER corporate strategy
Pursuing more sustainable production systems and more effective energy management have been important components of the HÜBNER Group’s corporate strategy for decades. Back in 1993, the largest production hall at the Kassel headquarters was opened with a sustainable timber-based construction and featuring a grass roof. In the future, further areas at HÜBNER Group locations will be examined for the possible development of photovoltaic systems.
