Smarter power for concrete batching - Hybrid systems that cut costs and boost efficiency

Concrete is essential to infrastructure development, but producing it, especially in mobile batching plants, requires reliable and flexible power.

These operations often take place in remote or temporary locations where access to the electrical grid is limited or unavailable. Diesel generators have traditionally served as a reliable power source in such settings, though evolving energy needs and technologies are prompting consideration of complementary solutions that can work alongside or in place of traditional systems.

Advantages of hybrid power, instead of diesel only power in mobile concrete plants:

Low fuel consumption by addressing fluctuating power demands.
Reduced maintenance by avoiding frequent cycling and inefficient load handling.
Managed cost volatility tied to diesel prices and unpredictable usage patterns.

Hybrid power integration for concrete batching application

Hybrid power integration with Atlas Copco

To address these operational demands, a mobile concrete plant implemented a hybrid energy system provided by Atlas Copco. The setup featured:

QAS+ 450 diesel generator: A high-capacity unit for peak loads.
ZBC 250-575 energy storage system: A battery-based system to manage variable demand.
ECO control system: A smart interface that optimizes generator runtime and battery usage.

This setup ensures that the generator runs only when needed—either during peak demand or to recharge the battery—always at optimal load levels.

Fuel and cost savings

The hybrid system delivered immediate and measurable results:

7,400 liters of diesel saved in the first 44 days.
Projected annual savings of €66,000 in fuel costs.
Reduced wear and tear on generator components due to fewer runtime hours.

By smoothing out power demand and minimizing generator use, the plant achieved better control over its energy costs and equipment performance.

Why hybrid systems make sense for concrete operations

This application demonstrates the practical benefits of hybrid power systems in mobile concrete batching:

Lower fuel consumption
Reduced maintenance frequency
Improved load handling
Greater operational control

For concrete producers looking to streamline operations and manage costs more effectively, hybrid energy systems offer a clear advantage. Contact one of our experts to learn more.