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

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