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Technical and Economic Approaches to Design Net-Zero Energy Factories: A Case Study of a German Carpentry Factory

Author

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  • Pio Alessandro Lombardi

    (Energy Systems and Infrastructures, Fraunhofer Institute for Factory Operation and Automation IFF, 39106 Magdeburg, Germany)

Abstract

As many German SMEs approach the end of their photovoltaic (PV) feed-in tariff period, the challenge of maintaining economic viability for these installations intensifies. This study addresses the integration of intermittent renewable energy sources (iRES) into production processes by proposing a method to identify and exploit industrial flexibility. A detailed case study of a German carpentry factory designed as a Net-Zero Energy Factory (NZEF) illustrates the approach, combining energy monitoring with blockchain technology to enhance transparency and traceability. Flexibility is exploited through a three-layer control system involving passive operator guidance, battery storage, and electric vehicle charging. The installation of a 40 kWh battery raises self-consumption from 50 to 70%, saving approximately EUR 4270 annually. However, this alone does not offset the investment. Blockchain-based transparency adds economic value by enabling premium pricing, potentially increasing revenue by up to 10%. This dual benefit supports the financial case for NZEFs. The framework is replicable and particularly relevant for low-automation industries, offering small and medium enterprises (SMEs) a viable pathway to decarbonization. The results align with the European Clean Industrial Deal, demonstrating how digitalization and industrial flexibility can reinforce competitiveness, sustainability, and digital trust in Europe’s transition to a resilient, low-carbon economy.

Suggested Citation

  • Pio Alessandro Lombardi, 2025. "Technical and Economic Approaches to Design Net-Zero Energy Factories: A Case Study of a German Carpentry Factory," Sustainability, MDPI, vol. 17(17), pages 1-29, September.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:17:p:7891-:d:1740333
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    References listed on IDEAS

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