Article summary in 45 seconds
- Plants that start energy transformation with an audit – not equipment purchase – achieve ROI that is 30–50% shorter and avoid the most common mistake: oversizing or mismatching BESS and PV to the real load profile.
- EAB Solutions' free energy analysis delivers concrete figures within 48 hours: how much you lose on contracted-power charges and exceedance penalties, how much you can safely reduce contracted power, and which investment scenario is justified for your plant.
- Data you already have – invoices and AMI meter readings – are enough for a preliminary analysis. Expensive hardware or a new IT system are not prerequisites to start.
- EAB Solutions provides a free preliminary analysis for plants with contracted power from 200 kW and annual consumption above 500 MWh.
Table of contents:
- What is an energy audit and how does it differ from a basic bill review?
- Why plants that skip the audit overpay for BESS and PV
- What exactly does EAB Solutions' free energy analysis include?
- From analysis to project – what does the decision path look like?
- Three types of plants that benefit most from an audit
- Most common audit findings – what really hides in your bills
- FAQ – frequently asked questions
What is an energy audit and how does it differ from a basic bill review?
An electricity bill is a settlement document, not a diagnostic tool. It shows totals, not causes. A plant that analyses invoices only knows how much it paid – but not when and why it generates power peaks, whether contracted power is correctly sized, or which processes account for which share of consumption.
An energy audit is a process that answers questions the bill does not ask. For a production plant this means primarily: analysis of the power profile at 15-minute resolution over at least 12 months, identification of peak patterns and their causes, mapping of process loads, and verification of whether current contracted power and distribution tariff are optimized for the actual demand profile.
Why plants that skip the audit overpay for BESS and PV
The most common mistake when deploying EMS, BESS or PV is sizing system parameters from installed machine power, nameplate data or – at best – a one-month meter reading. Result: a system oversized by 40–80% or mismatched to real exceedance patterns.
Oversizing is not just wasted CAPEX. A BESS with too much capacity operates on partial cycles, shortening its lifetime versus design. A system that is too small does not eliminate exceedances – the plant pays for equipment and still gets penalties on the invoice.
What exactly does EAB Solutions' free energy analysis include?
EAB Solutions' free preliminary analysis is not a sales brochure with generic estimates. It is a structured report based on the plant's real data, delivered within 48 hours of receiving input documents.
| Analysis element | What we deliver | Input data |
|---|---|---|
| Energy cost profile | Bill breakdown: active energy, contracted power, grid charges, exceedance penalties – with percentage share of each component | 12 months of invoices |
| Contracted power exceedance analysis | Number of events, depth and duration of exceedances, historical cost and 12-month projection | 15-minute AMI meter or SCADA data |
| Contracted power renegotiation potential | Recommended new contracted power with risk analysis; estimated annual savings on fixed DSO charge | 15-min profile, 12 months |
| BESS sizing scenario | Recommended BESS capacity and power (3 variants: min / opt / max) with estimated peak-shaving effect and CAPEX per variant | Exceedance profile |
| PV potential | Estimated optimal PV capacity, self-consumption without and with BESS, annual PV savings | Annual consumption, location, daily profile |
| Subsidy analysis | Available programs (KPO, NFOŚiGW, regional), indicative intensity, documentation requirements for plant profile | Legal status (SME / large), location, PKD code |
| Simple payback (3 scenarios) | ROI without subsidy / with 40% subsidy / with 55% subsidy – for optimal system variant | All of the above |
What documents are needed?
- Energy invoices for the last 12 months (PDF scan is sufficient)
- 15-minute AMI meter data – available free via the DSO portal or on request from your energy supplier
- Current contracted power and distribution tariff information
- Basic plant data: industry, number of shifts, planned investments over 5 years
If you do not have 15-minute data – contact us. We will help you obtain it.
What preliminary analysis can and cannot do – limits of precision
Preliminary analysis based on AMI meter data is fast and non-binding – but has one important limit: the AMI meter records aggregate demand at the connection point, not per process. For a single-hall or single-site plant that is enough. For a plant with several halls, independent production lines or several supply points, the preliminary report will show when peaks occur but may not identify which process is the source.
In practice: BESS sizing from preliminary analysis is based on the aggregate profile – sufficient to assess profitability and choose an investment variant. Precise load allocation to processes and optimal sub-meter placement requires an audit with a measurement campaign. We always inform complex plants of this limitation when delivering the preliminary report.
From analysis to project – what does the decision path look like?
One common reason for postponing energy transformation is not knowing where to start. The diagram below shows a typical path from first contact to full deployment – with a clear distinction between what happens before any investment budget is committed.
| Stage | Scope | Time | Cost for plant |
|---|---|---|---|
| 1. Free preliminary analysis | Potential report: cost profile, exceedances, BESS/PV recommendation, 3 ROI scenarios | 48 h | Free |
| 2. Meeting and verification | Results review, data verification, plant priorities refinement | 1–2 days | Free |
| 3. Feasibility study and subsidy application | 15-year techno-economic model, KPO/NFOŚiGW documentation, application submission | 6–10 wks | Included in EAB project |
| 4. Technical design and delivery | BESS selection and order, PV installation design, EMS integration schematic; in parallel: DSO connection conditions change request (required for BESS – DSO wait time: 30–90 days, not included in installation schedule) | 10–18 wks + 30–90 days DSO (parallel) | Project CAPEX |
| 5. Installation and commissioning | BESS installation (2–3 days), PV installation (2–4 wks), EMS integration and commissioning | 3–6 wks | Included in CAPEX |
| 6. Continuous monitoring | Remote analytical supervision 24/7, algorithm updates, monthly reporting | Ongoing | Service subscription |
Key point: stages 1 and 2 are free and non-binding. The decision to launch the project and CAPEX is made only after stage 2 – when the plant has concrete figures, not estimates.
Three types of plants that benefit most from an audit
Type 1: Plant with a high bill but no insight into its structure
The energy manager or CFO knows the plant pays 'a lot for electricity' – but not how much is contracted-power charge, how much are exceedance penalties, and how much is the actual active energy price. For this profile the audit works like an X-ray: it shows which line items have reduction potential and of what magnitude.
Typical finding: at current active energy prices (market 2025–2026) structural DSO and capacity charges typically absorb 55–65% of a B23 bill. This share changes dynamically: at high spot prices (as in 2021–2022) it drops to 40–50%; at low prices it can exceed 70%. Negotiations with the supplier concern only the active energy price component – less than half the bill under current market conditions.
Type 2: Plant planning BESS or PV investment within 12–24 months
Management is convinced about investment but unsure of the optimal configuration: how large a BESS, what PV capacity, whether to combine both or start with one. Preliminary audit removes design uncertainty and provides data the system designer would have to collect anyway – except free and before the purchase decision.
Typical finding: planned BESS 500 kWh is 40% too large for the real exceedance profile. Optimal variant is 300 kWh – CAPEX savings of PLN 250,000–350,000 with the same peak-shaving effect.
Type 3: Plant applying or planning to apply for KPO / NFOŚiGW subsidies
Typical finding: the plant meets conditions for 55% subsidy intensity (SME status + support area location), not 40% as originally assumed – a difference of PLN 150,000–300,000 on an average project.
Most common audit findings – what really hides in your bills
Based on analyses and audits conducted by EAB Solutions in production plants with consumption of 0.5–15 GWh, below is a summary of findings that recur most often and have the greatest financial impact.
| Finding | Frequency | Typical financial effect | Corrective action |
|---|---|---|---|
| Contracted power inflated 15–35% above real maximum demand | 72% of audits | PLN 30,000–90,000/year overpayment on fixed DSO charge | DSO renegotiation after 6 months of EMS data |
| Repeatable exceedance penalties from 2–3 processes (start-ups, presses, furnaces) | 61% of audits | PLN 25,000–130,000/year; often unnoticed for years | EMS with prediction + BESS for peak shaving |
| PV self-consumption below 50% with existing installation without BESS and EMS | 54% of audits with existing PV | Loss of PLN 30,000–80,000/year vs. EMS potential | EMS integration with PV inverters; BESS as solar surplus buffer |
| Missing excise relief at consumption >1 GWh/year (Art. 31d Polish Excise Tax Act, legal status: 2026) | 38% of audits | PLN 15,000–45,000/year unused tax relief; verification with tax advisor mandatory – rules subject to change | Application to relevant tax office; eligibility check with tax advisor |
| Distribution tariff mismatched to production profile (e.g. B23 instead of B21) | 29% of audits | PLN 20,000–65,000/year difference in zone rates | DSO tariff change cost-benefit analysis |
Important note: the findings above are independent and cumulative. A plant where the audit identifies all five may face energy cost reduction potential of PLN 120,000–400,000 per year – before any decision to invest in BESS or PV.
How much is your plant actually losing – and what can you do about it?
Free energy analysis in 48h – concrete figures from your data, not industry estimates.
- Potential identification: contracted power, exceedance penalties, PV, BESS, subsidies.
- Ready financial model with 3 ROI scenarios – for your CFO or management board.
→ info@eabsolutions.com.pl | ul. Domaniewska 44, 02-672 Warsaw
FAQ – frequently asked questions
The EAB Solutions preliminary report contains concrete figures and recommendations regardless of whether you decide to work with us further. In some cases the analysis shows that the plant is not ready for BESS or PV investment (e.g. consumption too low, planning horizon too short) – and we communicate that outcome honestly. The purpose of the analysis is to provide data for decisions, not to push hardware sales.
Standard turnaround for the preliminary analysis is 48 hours from receipt of complete documents. For plants with a complex profile (several supply points, own GPZ substation) it may take up to 5 business days. We deliver a PDF report with an Excel presentation containing a financial model – ready for your finance department or controller.
15-minute data is available free of charge for every consumer on the B23 tariff – it is recorded by AMI meters installed by the DSO. You can download it yourself via the distributor portal (PGE Dystrybucja, Tauron, Enea, Energa, innogy/E.ON) or ask your energy supplier to provide it. EAB Solutions can help obtain data directly from the DSO – give us the NMK (point of consumption number) from your invoice and we will handle the rest.
The audit is a technical document, not a compliance inspection. Its purpose is to identify optimization potential, not to assess regulatory compliance. Any issues found incidentally (e.g. incorrect metering, outdated installations) are treated as information for plant management – they are not passed to regulators and do not affect eligibility to apply for subsidies.
Yes – EAB Solutions signs a confidentiality agreement (NDA) before the plant shares any data. This applies to both the preliminary analysis and later project stages. Meter and energy invoice data do not contain personal data, but we understand that the power demand profile can be sensitive business information, especially in chemical, defence and FMCG sectors. On request we run the entire analysis anonymously, without the plant name or location – results remain equally precise.
Especially in that case. Our data shows that more than half of plants with an existing PV installation without EMS and BESS integration achieve self-consumption below 50% – meaning they export more than half of generated energy to the grid at buy-back rates while purchasing energy at peak tariff rates at the same time. A profile audit will identify the gap between the potential of the existing installation and its actual use and calculate whether adding BESS and EMS is financially justified.
See also
Why Monitoring Is Not Enough – How Intelligent Energy Management (EMS) Differs from Classic Measurement Systems
Visualizing energy consumption alone won't lower bills. Classic monitoring shows how much and when you consume energy. Intelligent Energy Management System (EMS) goes a step further: it forecasts, decides and controls devices in real-time.
Why energy monitoring is no longer enough in a production plant
Monitoring consumption is a good starting point, but in the reality of industry it is far from sufficient. An intelligent EMS will stop costs that a consumption chart alone will not.
Energy Prediction in Industry – How Algorithms Predict Peaks and Energy Prices
Rising energy costs, tariff sensitivity, and the growing role of renewables mean industrial plants must act faster, more precisely, and more consciously. Energy prediction enables cost reduction, production stabilization, and limiting the impact of price fluctuations.