Smarter Energy Solutions
VSN Steels - Forging ahead with smarter energy solutions
VSN Steel has been at the forefront of heavy steel profiling for over 60 years. Based in Birmingham, the business supplies precision-cut steel plates to sectors including energy, renewables, petrochemicals, and structural engineering. With unique capabilities to handle plate thicknesses of up to 650mm, VSN is one of only a handful of UK firms able to meet the demands of large-scale steel profiling. But as global supply chains and energy markets shifted, VSN faced mounting cost pressures and an urgent need to reduce its carbon footprint.
Powering through the pressure
Rising energy prices were the most significant challenge. The impact of global events, including the war in Ukraine, saw electricity costs spiral. What was once a manageable monthly bill for VSN Steel threatened to become an unworkable £20,000 to £30,000 expense – putting the viability of key operations at risk. To stay competitive and protect jobs, the business had to act.
VSN installed energy monitoring across its plant, identifying older machines consuming excessive power. Adjustments to processes and machinery use quickly delivered savings, but management knew more substantial changes were needed.
To dramatically cut reliance on expensive grid energy, a new 155kW rooftop solar array and 280kW battery system were installed. The battery allows the business to store solar energy and shift demand, using cheaper night-time electricity to charge and relying on stored power during peak daytime hours. Even in winter, the system generates around 50kW, with the battery covering early-morning operations.
Results that stack up
The upgrades are already transforming VSN Steel’s operations. In the first six months, the solar system generated an additional 43 MWh of electricity. The company now expects to save £25,000 to £30,000 annually on energy bills. With grant funding covering half of the project cost, the solar array should pay for itself within 18 months, with the battery investment recouped in under five years. VSN isn’t stopping there. Plans are in place to switch from natural gas to LPG, cutting carbon emissions and methane production.
The business is also investing in site redevelopment and new machinery to drive further efficiencies.
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