Smart Energy & Uptime Hub

Modern industrial plants run on two lifelines: uninterrupted machine uptime and affordable, flexible energy. Yet factories still lose millions to unplanned stoppages and peak-price power, while viable second-life EV batteries sit idle or head straight to recycling. Technical fragmentation, separate maintenance systems, rigid energy controls, uncertain battery health, keeps most sites from unifying these assets into a single, circular solution.

 Orblytic’s project tackles this gap head-on. We are building a full-scale demonstrator that marries predictive-maintenance sensors with an AI energy-management controller and modular, second-life battery energy storage container.

The goal: to prove that pairing smart diagnostics with repurposed batteries can slash downtime, flatten energy peaks and unlock a profitable pathway for reused cells; turning every kilowatt and machine-hour into circular value.

Objectives:

• Build a small scale container modular designed battery unit that factories can use on-site.

• Connect the battery modules to Orblytic's upcoming AI energy management system (EMS) and our predictive maintenance sensors.

• Show how the trio of sensors, smart EMS and a battery energy storage system (BESS) cuts both energy bills and costly uplanned downtime for industrial customers.

Technical development:

• A plug-and-play battery container that the EMS can charge or discharge automatically, based on external API, command logic and machine-health alerts from our sensors.

• Demostrator concept of a 10-ft container BESS which satistfies the needs of industrial actors.

Economic fit:

• Cost Benefit model – compare CAPEX/OPEX, residual value and lifecycle cost of second-life- BESS vs. virgin-cell systems and diesel/peak-shaving alternatives.

• Adoption incentives – identify financing mechanisms (lease-to-own, energy-as-a-service), incentive schemes and circular-economy credits that improve bankability.

Methodology/Approach:

• Collaborate/research - Talk to battery suppliers, visit pilot factories as to gather battery module communication protocols and identify potetial problem scenarios.

• Building the modular BESS(part 1) - Assemble one modular BESS, install sensors on "phantom loads" linking all communication together to a test version of Orblytic's EMS.

• Building the modular BESS (part 2) - Live testing at an industrial partner facility with integration of Orblytic predictive maintenance sensors, EMS and BESS linking all communication together. Testing of EMS algorithms for peak shaving, fault-avoidance and flexibility services readiness.

Economic analysis:

• Real-time tracking of energy savings, downtime events, battery degradation.

• LCOE & TCO modelling; sensitivity to market prices and module cost.

• Circularity/LCA assessment of material flows.

Expected results:

• Factory experiences lower peak-energy costs and a significant reduction in downtime.

• Battery resuse win: Second life modules get extra working years before recycling.

• A modular system that can be upgraded or downgraded in terms of capacity dependant on the need.

By uniting predictive sensor insights, AI-driven EMS, and battery energy storage systems, Orblytic will give industries a single tool to spend less on power and avoid costly downtime, while giving used EV batteries a valuable second use case.