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the lessons are becoming clear, and they extend far beyond theoretical efficiency gains.
And yet, the shift to DC isn’t simply about efficiency; it’s about resilience. Throughout its first years of operation, the NExT Factory has maintained energy continuity even during grid disruptions, including “island mode” operation — when it temporarily disconnects from the main grid and relies solely on internal sources. Central to this capability is its advanced battery storage system, featuring 405 kWh of capacity and 270 kW of output. Notably, the system integrates second-life lithium-ion (NMC) cells, batteries previously used in other applications, now repurposed to extend their lifecycle. With intelligent thermal management and a projected lifespan of 15-20 years, the unit helps flatten peak demand and en - hance energy independence while contributing to circular economy goals.
At the heart of this shift is a straightforward principle: Energy should flow directly and efficiently, with as few conversions as possible. In traditional AC-based systems, power from solar panels or batteries — which naturally generate work on DC — must first be converted, leading to losses and complexity. By using a DC grid internally, the NExT Factory avoids many of these conversions. The result is significant: photovoltaic (PV) systems connected to the factory’s DC grid have demonstrated an 8% boost in efficiency compared to equivalent AC configurations. This is achieved by reducing complexity instead of adding components. But the advantages don’t stop there. Energy storage, an- other critical component in resilient industrial power, also benefits from DC architecture. Battery systems connected via DC experience 3-4% less energy loss, while high-demand robotic systems have seen power consumption drop by as much as 21%. Cable sizes can be reduced thanks to higher operating voltages, cutting copper usage by up to one-third. Taken together, these changes contribute to a potential 37% reduction in overall transmission losses — figures that are not theoretical but documented through real-world operation.
This storage solution is optimized through an inhouse-devel- oped energy management system (EMS) designed specifical - ly for DC environments. Processing over 5,000 data points per second, the EMS uses machine learning and digital twin simulations to anticipate load fluctuations, shift energy usage, and coordinate between generation, consumption, and storage. It’s not a black box; it’s an evolving intelligence layer, fine-tuned to deliver stability, cost savings, and deep system insight. Technically, one of the most compelling breakthroughs has been in voltage management through so-called droop con- trol strategies. These methods are used to distribute power load across multiple sources. While the linear droop curve (LDC) offers a simple proportional approach, Schaltbau has tested and validated a more advanced interleaved droop curve (IDC), which provides non-linear, multi-stage control.
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