How manufacturers can avoid a power outage

For manufacturers and their supply chain partners, there is no greater threat to productivity and deliverability than a power outage. In fact, it’s been estimated that manufacturing losses can reach up to $1 million per hour due to disrupted production. And we know why. Nothing can get done in the dark. Without power, every task stops—from the assembly line to prototype testing to warehouse logistics to sales presentations and invoicing. Everything comes to a halt and when timelines are essential to keep the wheels turning across the supply chain (both internally and externally), the disruptions caused by power outages can be devastating.

Knowing the reasons behind the outage might make for interesting conversation but it won’t reduce the losses that a business will face. Whether it was caused by a severe weather incident like a hurricane or wildfire or an overburdened power grid, manufacturers and the supply chain partners they rely on must find a way to keep their power running, even when everyone else in the area is down. It’s especially imperative since the average power outage lasts five hours.

Being proactive on backup energy is no longer a “why” should we but “when” should we because backup power systems are now easy-to-install, efficient to run and affordable. Here’s what manufacturers should consider and how they work.

Automatic standby generators are located outdoors so they don’t take up valuable interior space. They need to be installed on a concrete slab at least five feet away from windows, doors and fresh air intakes. Connecting to a natural gas line is usually the most convenient fuel source but standby generators can also run on liquid propane or diesel. In any case, a standby generator is wired into the electrical panel with an automatic transfer switch (ATS), which monitors the utility line and immediately recognizes when power is lost. When that happens, it will trigger the unit to automatically start within seconds so business can continue without interruption. Once utility power returns, the ATS will automatically switch back to grid power. Employees won’t have to do a thing before, during or after the outage.

As far as how big a unit you will need, that will depend on how much you will want to keep functioning. Knowing what will be most important for production, communication and security will be key to designing your system. Your vital needs might include communications and computer systems for dispatching and logistics routes or warehouse lighting for safety, security and inventory management. Being proactive will make it possible for you to keep critical functions running continuously.

Battery backup systems are most often paired with solar panels—but they work just as well without a solar system. Batteries are a reliable alternative when a standby generator can’t be installed or if an interior location is required. Additionally, a battery system can be scaled over time to provide even more power during an outage. Battery systems can store energy from solar panels or from the grid and this energy can be tapped when it’s needed. They include an inverter with an integrated ATS to sense a grid outage and switch between the primary power source and the backup battery system. Batteries are compact, stackable and can easily attach to the wall of a storage room or the outside wall of a building. With batteries, the switchover is instantaneous and silent, you may not even know the power went out. Plus, batteries have zero emissions.

Another consideration for manufacturers and supply chain companies is that battery systems can also lower electricity expenses through rate arbitrage. Switching over some or all operations to battery energy during peak rate times allows companies to manage their utility costs, adding to the return on investment and shrinking payback timelines. Don’t wait until the lights go out—the time to act on a generator or battery backup system is now, before an outage occurs.

About the author

Donna McGinnis

Donna McGinnis is director of marketing at Briggs & Stratton Energy Solutions, delivering energy resilience and energy efficiency to businesses and homeowners. With more than a decade working in the residential and commercial backup power industry, she is on the forefront of power outage solutions, including backup battery trends as more homeowners and businesses embrace this emission-free technology that can be used as a supplement to utility power or to go completely off grid.

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