In the interview with Michael Hartmann, Technical Product and Project Manager at eSaver GmbH

The German electricity market is currently facing many challenges. On the one hand, the entire industry is moving towards renewable energies, focusing on solar and wind power. On the other hand, electromobility is experiencing constantly growing demand. In this context, expanding charging infrastructure and integrating electric vehicles into the power grid are important topics. Aspects such as decentralized energy generation and energy storage, digitalization with smart grids, and much more are additionally occupying the players in this field. However, one conflict factor is currently at the top of the agenda for companies, but also in the private sector: high and still rising electricity costs. When it comes to energy trading and prices, but also regarding our current grid quality, good advice is expensive. While we may not notice the fluctuations in feed-in in everyday use, many applications in the operational environment have problems with them, and bottlenecks can, in the worst case, even lead to production downtimes.

eSaver, based in Ehningen, promises to provide a solution to this dilemma. The provider has been working for many years on holistic solutions for company-wide energy supply through clever combinations of hardware and software. The associated power savings and grid optimization have the potential to reduce in-house business consumption—while maintaining the same performance and with a payback period of three to five years—by up to 24%. How this can be achieved individually for customers and what makes the eSaver method special is explained by Michael Hartmann in an interview with DIGITAL FUTUREmag.

DIGITAL FUTUREmag: Mr. Hartmann, in the more than 160 interviews we have conducted with IT experts, managing directors, and decision-makers for DIGITAL FUTUREmag, there has never been a topic that so strongly demonstrates the possibilities of digitalization in everyday life with such tangible effects or results in terms of sustainable Green IT. You have been driving the eSaver project forward for a long time. What drives you personally the most in this endeavor?

Michael Hartmann: Every morning, I get up with the good feeling that my work is truly meaningful—I help companies permanently reduce their energy costs while also contributing to environmental and climate protection. After all, using less electricity also reduces CO₂ emissions. Our customers benefit from significant advantages: with eSaver technology, they save electrical energy, improve the quality of the local grid, extend the lifespan of electrical consumers, and even prevent failures caused by micro-blackouts. All of this leads to substantial cost savings. In terms of the energy transition, it is crucial to utilize all potential savings to reduce the effort and investment costs in sustainable energy generation systems. Just imagine the impact if all (large) consumers of electrical energy could save even just 10% thanks to the eSaver process! Especially since the goal is to shift energy consumption in mobility and heating technology from fossil fuels to electrical energy, every opportunity for savings must be considered.

DIGITAL FUTUREmag: According to figures from the German Federal Ministry for Economic Affairs and Energy (BMWi) from 2020, industrial electricity consumption accounted for around 43 percent of Germany’s total electricity consumption. Even if only a small proportion of companies in this sector used eSaver, immense cost savings could be achieved and a significant amount of CO₂ reduced. Why has your solution only been adopted by a few players in the industry so far?

Michael Hartmann: Unfortunately, our groundbreaking technology is not yet as well known or widespread as, for example, PV systems or LED lights. That’s why we have to do a lot of convincing with potential customers: we rely on numerous references from different industries and on the fact that TÜV Rheinland, after a long-term measurement, confirmed that the eSaver process achieves significant energy savings while also contributing to grid stability and increased supply security. Once an eSaver system is installed, we can’t always rely on recommendations, as some customers see the savings they achieve as a competitive advantage and don’t want to “go public” with them.

DIGITAL FUTUREmag: You mention a maximum electricity saving of 24% – that’s quite a lot. Could you briefly explain the principle behind these savings?

Michael Hartmann: A saving of 24% is something we achieve in individual cases – that’s a peak value we’re proud of. Typically, the savings are between 10 and 18%. This is mainly based on the magnetic field technology used in eSaver systems:
The heart of this technology is a specially developed transformer with a unique structure. In the iron core of this transformer, a magnetic field builds up that absorbs the unwanted harmonics in the local power grid and returns the energy contained in them to the consumers. We like to refer to this process as “recuperation”. At the same time, thanks to this specific design, we carry out automatic voltage regulation – to both saturate the magnetic field and keep the voltage at an optimal operating point that is dependent on the system. This reduces losses in cables, connection points and electrical components in the local grid, which in turn saves energy.

DIGITAL FUTUREmag: To what extent do modern software and hardware support this technology?

Michael Hartmann: When assembling our switchgear combinations, we only install proven components from renowned manufacturers. Our systems are equipped with a Siemens S7 controller and our own developed software, which processes the input of various electrical parameters and thus ensures the fully automatic control process. Our technicians or the system operator can view measured values and operating statuses via a touch panel in the control section of the eSaver systems. At the same time, the data recorded by the system is transmitted to our server in Ehningen via a mobile data connection. This allows us, for example, to support a maintenance technician on site in the event of a fault and, if necessary, jointly identify the cause. It is also possible to connect the system to a customer's site-specific energy management system via an interface.

DIGITAL FUTUREmag: In addition to industrial companies, your clients also include larger public administration facilities or, for example, a savings bank. Who is eSaver suitable for and from what consumption level does its use pay off?

Michael Hartmann: Our systems are generally worthwhile for all electricity consumers in the sectors mentioned. The rule of thumb: From a monthly electricity consumption of around 10,000 kilowatt hours, an eSaver system is cost-effective, with a good payback period.

DIGITAL FUTUREmag: In your brochures, you state a payback period of 3-5 years. Does this already include ongoing costs such as maintenance?

Michael Hartmann: Maintenance costs are not included – they are so low that they are negligible. By the way: Due to rising electricity prices, there are more and more cases with a payback period of less than 3 years. The eSaver has the advantage that it can be financed from the savings it generates.

DIGITAL FUTUREmag: What other benefits does your approach offer in addition to the cost savings?

Michael Hartmann: First, our systems improve the quality of the local power grid. Thanks to recuperation and damping of harmonics, electrical consumers heat up less, which extends their service life. In addition, this avoids any negative impact on protective devices.

Second, the use of our systems also offers advantages for the electricity supplier or grid operator: As a so-called "grid-serving system", our technology prevents grid feedback from a local grid from entering the general power grid. Lines, connection points and components are subjected to less stress – a welcome benefit for grid operators and electricity suppliers.

Thirdly, our systems have the ability to bridge micro-blackouts of up to 30 milliseconds, and in some cases even up to 60 milliseconds with a certain over-dimensioning of specific customer systems. This prevents the failure of sensitive controls. The consequences of such an event would be dramatic: machine processes are interrupted, CNC programs stop, leading to production errors and even tool breakages. Machine operators or maintenance personnel must restart the systems. All of this is expensive. Companies struggling with such micro-voltage failures should definitely contact us.

DIGITAL FUTUREmag: Are there government funding options available for purchasing or operating the system?

Michael Hartmann: Yes, since 2019, the BAFA has recognized our technology as eligible for funding and subsidizes the investment in an eSaver system by 40% for SMEs (small and medium-sized enterprises) and by 30% for large companies – a significant advantage for our customers. The application is submitted in Module 3 “MSR, sensors and energy management software.” We are happy to support our customers here by handling the entire application process on their behalf, including providing all necessary documents. This funding applies to financing options such as purchase, hire purchase, and contracting (here: in favor of the contractor); it does not apply to leasing.

DIGITAL FUTUREmag: How would you describe the installation and setup of the system? What effort would companies need to make if they decide to use your technology?

Michael Hartmann: The time required for on-site installation varies depending on the scope of services. There is a significant difference, for example, between installing one system or several systems at a single location. Factors such as the installation situation and the required cable routing also play a role.
In a standard situation – installing a single system – we need about one day to place and route the cables and another day to integrate and commission the eSaver. On the third day, we carry out function tests and train the customer’s responsible personnel in operation and technology. Overall, the effort for companies is manageable: to create an initial quote, a few data points need to be gathered, such as annual electricity consumption, electricity price, load profile, and transformer sizes and configurations. We are happy to handle the BAFA application as a service for the customer to relieve them of this burden. For on-site installation, scheduling coordination is required.

DIGITAL FUTUREmag: Our magazine is read by many software companies and data center operators. The power consumption of the latter, in particular, is quite high. Wouldn’t using the eSaver be practically mandatory in their case?

Michael Hartmann: The eSaver process is also useful for data centers. It would be desirable if corresponding regulations made the use of our systems mandatory. This is currently not the case. Companies decide for themselves whether to include the eSaver in their budget planning or prioritize other investments. First of all, it is important that companies or municipalities even learn about the many positive effects of eSaver technology. All the more, I am pleased to present our company, our product, and how it works in your magazine.

DIGITAL FUTUREmag: Thank you for this very exciting, progressive, and forward-looking interview. I wish you continued success and hope that people responsible for cost savings in companies and stable local networks will take a closer look at your contribution.