Fronius UK Ltd (Solar Energy)

In 2022, Fronius invested EUR 187 million in expanding and converting the production site at Sattledt (Austria) and the competence center for inductive components in Krumau (Czech Republic) – and will increase investment to more than EUR 230 million in the coming year. This will result in additional production lines, jobs, and a stable manufacturing situation.

Fronius is investing hugely in expanding production. “We have increased total floor space from 41,000 m² to 69,000 m². Our production facilities are operating constantly at full speed to meet rocketing demand the best we can,” says Martin Hackl, Global Director Marketing and Sales, Business Unit Solar Energy, Fronius International GmbH. High value creation in Europe is top priority for Fronius; this is the only way that high quality and safety standards can be ensured. “95 percent of our contract partners come from Europe,” states Martin Hackl.

New Production Lines
The northern expansion of the production plant in Sattledt, Austria, is already up and running. The Fronius Tauro has been manufactured there since the middle of August. The existing manufacturing facilities are being converted, resulting in an additional production line for the Fronius GEN24 Plus this year. Two more will be added in 2023. “The additional production lines help us to meet the high demand”, explains Martin Hackl.

High Output Versus PV Boom
„Output at Fronius is higher than ever,” says Martin Hackl. In 2022, a total of almost 32,000 inverters per month were produced. By the end of 2023, this should be more than 52,000 per month, a rise of more than 65 percent. This meets a real boom in PV. “Photovoltaics are more sought-after than ever before, and demand is exploding,” says Martin Hackl. At the same time, the pandemic presented companies around the world with new challenges. Even Fronius was not spared. “Despite difficult circumstances such as unstable supply chains and shortages of components and staff, we were able to secure supply and stabilize production,” reports Martin Hackl.

Sustainable Investment at All Sites
Investment in energy-saving technologies and conscious consumption of resources are principles that are firmly established at Fronius: Two ice tanks are used at the production site at Sattledt for heating in winter and cooling in summer. It is currently the largest system of its type in Europe. A further highlight is the fully automatic high-bay warehouse, which provides space for 7,000 pallets and 12,500 containers for small parts.

At the Czech site in Krumau, the next phase of expansion is already being planned, even though the most recent addition has only just been finished. Plans for the next five years include a doubling of the workforce and a substantial expansion of production space.

Many of the 25 branches of Fronius Solar Energy are investing in the future over the coming year. For instance, Fronius Italy will put a new PV system and charging stations for electric cars into operation. At Fronius in Switzerland, field staff will be using twelve electric vehicles to get around from 2023. Fronius is also investing in new staff. Martin Hackl expects strong growth over the next two years: “We’re looking for around 1,300 new employees worldwide by the end of 2023.”

As sustainable as a project inverter can be

The results of the life cycle analysis for the Fronius Tauro could not be clearer: the environmental benefits exceed the environmental costs by a factor of up to 52, while in no more than ten months, the Tauro will produce more energy than was consumed to manufacture it. These are just two of the many outstanding results of the life cycle analysis demonstrating that the Fronius Tauro is “Designed to perform”.

Fronius’ sustainability experts spent eight months analysing the life cycle of the Fronius Tauro project inverter. Every step was examined, from the procurement of raw materials, through production and use, to disposal at the end of the product life cycle. Even the smallest aspects were carefully considered in incredible detail: “We evaluated 960 components with 5,050 parts and even etched components in sulphuric acid to be able to determine the weight of the semiconductors and gold elements inside even more precisely,” describes David Schönmayr, Project Manager R&D, Fronius International GmbH.

Scientifically-proven sustainability
The 8,400 results in total were subsequently verified by the highly regarded IZM Fraunhofer institute in accordance with ISO 14040 and 14044. “This is scientifically-proven sustainability. We deal solely with facts, because we want to know how we are doing and incorporate these results into future products,” explains Schönmayr.

Karsten Schischke, from IZM Fraunhofer, is also convinced by the results: “A life cycle analysis is not an end in itself, but should identify specific opportunities for improvement in the life cycle. This is exactly what the life cycle analysis of the Tauro [...] has achieved: the detailed analysis not only confirms the important positive contribution of PV inverters for the green transformation of the energy sector, but also identifies areas with potential for us to work on from the point of view of climate protection and the circular economy.”

Life cycle analysis delivers outstanding results
The results are undeniably impressive: the payback time of the climate impact (CO2 payback time) – in other words, the time until the inverter becomes climate neutral – is between five months and two years, depending on usage. Fronius Tauro also performs impressively when it comes to energy payback. The project inverter needs less than one year (0.34 - 0.83 years) to produce more energy than was consumed during its manufacture. Furthermore, up to 223,097 kg CO2-e are saved by the Fronius Tauro, equivalent to up to 200 flights between Vienna and New York.

“This is one of the key differences between Fronius and other manufacturers. We set ourselves apart through end-to-end transparency when it comes to the sustainability of our products. We are industry pioneers, both in terms of depth of detail and consistency of the life cycle analysis. And, our aim is to have the systems with the best carbon footprint,” says Martin Hackl, Global Director Marketing & Sales Business Unit Solar Energy, Fronius International GmbH.

From recycled materials to repairability

“Our customers are increasingly asking for life cycle analysis results. They want to know how much recycled material is in their inverter and what the situation is regarding repairability,” reveals Martin Hackl.

The Fronius Tauro is completely and fully repairable. Almost every part can be replaced, which also has a positive impact on service life. If, for example, a power stage set is replaced after ten years, up to 150 kg of CO2 is emitted. With our competitors, the entire inverter would have to be replaced, resulting in many times more CO2 being released into the atmosphere. This unique power stage set replacement option provides the ultimate in convenience for Fronius customers while also being good for the environment.

- From a sustainable vision to the largest business segment
- Photovoltaics boom leading to above-average growth
- Expansion of the Sattledt production site almost

It was in the early 1990s that Fronius first decided to focus on solar energy as a “technology of the future”. Still not taken seriously back then, the business unit has come to represent the most important pillar of the family company. Since value creation is set to remain in Europe going forwards, this growth is mainly showing itself in the Sattledt production site in Upper Austria.

Fronius, the family-owned company based in Upper Austria, is often associated with the booming photovoltaics industry. But it wasn’t always this way: if you look back at the first 30 years of its youngest “Solar Energy” business unit, you’ll see that it was only in recent years that this branch developed into the company’s new driving force. For a long time, what was once the “technology of the future”, solar energy, led a shadowy existence and managed to survive one of the worst crises in company history. But one thing at a time…

The beginnings of Solar Energy

In 1950, Fronius began developing both its battery charging technology and welding technology branches, experiencing its first major successes from the 1960s onwards. These culminated in the milestone that was the introduction of an unprecedented welding system in 1981. “At some point we were starting to look more and more like power-guzzlers,”, remembers CEO Elisabeth Engelbrechtsmüller-Strauß. “You have to realise that, back then, welding technology required vast amounts of energy. We wanted to ‘give back’ some of this power and started the initial trials with photovoltaic modules. These were the beginnings of the Business Unit Solar Energy.”

Thirty years later it seems as though there’s no getting away from green power generation using solar energy. However, these current successes were nothing but a pipe dream for a very long time, as Engelbrechtsmüller-Strauß explains: “In the early days, we were often portrayed as tree-huggers and had great difficulty finding a place for our systems on the market. To put it into context, we used to manufacture just one to two inverters per week.”

Europe’s energy supply in focus

The extent to which things have since changed and the reason why the Solar Energy business unit has overtaken even the Business Unit Perfect Welding are underpinned by the latest figures: with a planned output of 510,000 inverters this year, Fronius is the biggest manufacturer of prosumer solutions in Europe. There are already 3.4 million Fronius inverters in operation around the world generating 35.1 TWh of clean solar energy every year – the equivalent of 33 Danube power plants. The energy supply is becoming increasingly decentralised as customers themselves become producers – they generate their own electricity, use it locally and pass the surplus on to other consumers. External environmental factors such as high energy prices and Europe’s future self-sufficiency are noticeably driving this development.

“The focus here is always on the huge relevance of European value creation. Particularly due to the recent supply bottlenecks, Europe is trying to reduce its dependence on other markets,” explains Martin Hackl, Global Director Marketing and Sales, Business Unit Solar Energy, Fronius International GmbH. “This absolutely warrants our support here at Fronius. Over many years, we’ve been successively reducing on European expertise in areas such as microelectronics. This puts us at a disadvantage compared with our Asian competitors but, that being said, we need to look at this development with a critical eye since we’re creating a sustainable and independent energy supply from products that don’t just come from other continents. For us, sustainable solutions are of the highest priority and the best way for us to make these is by expanding our manufacturing activities in Austria and the Czech Republic. As a result, we can guarantee the highest social, environmental and quality standards. In terms of transport routes, products from other continents are anything but practical and sustainable.”

The expansion in Sattledt in figures
That’s why Fronius has based its production sites in Austria and Czech Republic and has never been focused on outsourcing – quite the opposite in fact: “Strategically speaking, we’re preparing for major growth in Europe and investing heavily in expanding our production and capacities,” says Hackl. The best example is the major production and logistics site in Sattledt, Upper Austria. Here, the current usable space covering 41,000 m² is set to be expanded by an additional 28,000 m². Overall completion is already scheduled for late July 2022, after which the new space will gradually be filled.

The highlights of the so-called northward expansion include the fully automated high-bay warehouse. It will be the future transfer point for incoming g

Fronius UK will be opening the doors to its Technology Centre in Milton Keynes to unveil the latest cutting-edge welding technology as it hosts its fifth Open House on 18th and 19th May.

Fronius has put together a wide variety of demonstrations across its range of products, solutions and applications and a programme of talks from specially selected guest speakers and industry partners. The event promises to be informative, hands-on and packed with fun and whether you are looking to review your welding processes, or find out what’s new, this is just the event for you.

This is a real opportunity to explore the world of Fronius and to see up close the most recent advances in welding technology, including the new iWave Multiprocess Pro, launched this January. This machine gives you full freedom to unleash your welding potential. In addition to all the TIG functions, you can weld all MIG/MAG process variants with a single system. If you want to weld faster, with less rework, you can try out the TransSteel Pulse range of MIG/MAG welding machines - and never have problems welding those hard to reach areas again with the new Fronius Flex-Drive. Hear from an expert on the development and possibilities of Wire+Arc Additive Manufacturing (WAAM), plus see some world leading automation and robotic welding solutions.

You can also be one of the first to see the all new Magic Cleaner 150/300. This innovative technology allows optimum reworking of TIG weld seams and stainless steel surfaces in a single step, with minimal impact on the material surface. The electrochemical cleaning devices make it possible to polish welds to a lustrous finish and permanently print logos and serial numbers on workpieces.

Whatever your welding challenge, you can use this day to come and talk to Fronius and see some of the solutions it has on offer, whilst enjoying a schedule of entertainment, a hot lunch and refreshments throughout the day.

“This event provides an ideal opportunity to visit our facility and understand the very latest solutions available on the market”. James Anderson, Director of Welding for Fronius UK comments, “We look forward to welcoming all those involved in welding. I would also encourage anyone currently experiencing welding challenges to come and talk to us about them to see where we could potentially help to improve processes.”

The day will also incorporate the company’s other two business units: Solar Energy and Perfect Charging. With the imminent increase in energy prices, take the opportunity to look at the company’s industry leading solar products and services including its hybrid solar inverter that recently won first place for efficiency in the Energy Storage Inspection 2021 and its new powerful yet robust, project inverter for high yields, the Fronius Tauro.

And if your operation uses any electric forklifts or warehouse trucks you can also find out how unique, intelligent battery chargers from Fronius can reduce your energy costs and CO2 emissions.
This is just a snippet of what you can expect to see on the day. To find out more, including which industry leading speakers you can expect to hear from, as and when they are announced, visit www.froniuopenhouse.co.uk

Due to the success of its previous Open Houses, the company has made the decision to spread this year’s event across two days to allow everyone the time and space to observe demonstrations safely, provide time to speak to experts and try out products were possible. Fronius UK will welcome guests from 9:30am until 3:30pm on both days.

Register to attend either day at www.froniusopenhouse.co.uk

Protecting your business is easier than you think. Fronius now offers businesses a PV Solar solution with no upfront investment that will save you money from day number one.

It’s not surprising that energy costs are a significant portion of a business’ overheads. This continues to be true despite the development of more efficient technologies as we encounter constant energy price hikes and as more electricity-reliant innovations emerge, such as electric vehicles. There is, however, a way not only to protect yourself from further increases, but to do so with no upfront investment.

Show me how

Specialising in the highly efficient and intelligent conversion and control of energy for over 70 years, Fronius has partnered with some of the UK’s biggest brands to deliver financial savings, carbon reductions and energy independence. Recognising that the upfront cost associated with a Solar PV investment was preventing companies from achieving enormous savings with the technology spurred the creation of a unique leasing system provided by the global inverter manufacturer.

Unlike Power Purchase Agreements, this model allows you to lease the equipment required to generate your own green electricity over a 15 year period, with the option of ownership thereafter (other options available).

Throughout the duration, your monthly payments will be lower than the cost of that same electricity if purchased from your energy supplier at today’s rate*. This enables you to make huge savings from the outset and protects you against increasing energy prices. Additionally, you would be the beneficiary of any available feed-in incentives. Furthermore – there is a production guarantee for the duration of the contract. This means that if the system produces less than guaranteed, you will be reimbursed for the underperformance – a risk-free arrangement for you.

After completing a thorough analysis of the premises and current electricity usage, one of their trusted partners will install the PV system on the roof of your premises to the highest specification.

High quality engineering drives everything that Fronius does, so you can be rest assured you’ll be getting the highest quality products from the very best manufacturers. There are no ongoing maintenance costs, this is all included. You won’t need to worry about maintenance or insurance of the system throughout the duration of the lease. It really is a win-win.

Whatever your business: Computers, printers, forklift charging, machinery, lighting, air conditioning, kettles; the list of energy hungry appliances is exhaustive and all contribute to a company’s running costs which can have a huge impact on profitability. You can quickly and easily boost you business’ bottom line and achieve immediate savings by significantly reducing your electricity costs with solar PV. What’s more, incorporating PV into an environmental management system could be a very positive step for companies pursuing ISO 14001 certification or for those just wanting to be greener.

Don’t miss out on the benefits of photovoltaics for your business because you have investment priorities elsewhere right now. Find out how much you could save by calling 01908 512300 today.