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Industrial Case Study

Air Itam Electronics Factory: RM74,000/Year Savings via Peak Shaving + Solar

Air Itam Industrial Zone, Penang
November 2024

Bill Reduction

8%

Annual Savings

RM 74,160

Payback

6.2 years (reduced to 4.1 years after GITA tax benefit)

CO2 Offset

285 tons/year

Trexon Energy Team profile photo - Solar Installation Specialists
· Solar Installation Specialists

The Challenge

High Maximum Demand charges (RM52k/month) due to CNC machines and peak-hour production. Monthly electricity costs exceeded RM78,000 despite energy audits.

Monthly Bill (Before)

RM 78,420

Annual Cost (Before)

RM 941,040

Pain Points:

  • •Maximum Demand charges: RM52,000/month (66% of bill)
  • •Peak production during TNB peak hours (8am-10pm)
  • •Unable to shift production schedule due to 24/7 orders
  • •Previous energy audit found no actionable savings
  • •Competitor in Bayan Lepas using solar—competitive disadvantage

The Solution

System Size

250 kW Solar + 150 kWh Battery (BESS)

Installation Time

12 days

Solar Panels:

JinkoSolar Tiger Neo (580W, 432 panels)

Inverter:

SMA Sunny Tripower CORE2 (250kW) + 150kWh LFP Battery

Special Features:

  • AI-powered peak shaving algorithm
  • Battery charges during solar peak, discharges during demand spikes
  • Real-time MD monitoring and alerts
  • GITA (Green Investment Tax Allowance) optimized—RM360k tax savings

The Results

Monthly Bill (After)

RM 72240

Annual Savings

RM 74,160

ROI

16% IRR (24% IRR post-GITA)

Environmental Impact:

285 tons/year (equivalent to removing 62 cars from roads)

TNB Bill Breakdown Analysis

Before Solar

Energy Charge (95,000 kWh @ RM0.365)RM 34675.00
Maximum Demand (1,250 kW @ RM41.60/kW)RM 52000.00
Service ChargeRM 7.20
KWTBBRM 346.75
ICPT Industrial SurchargeRM -8608.95
TotalRM 78420.00

After Solar

Energy Charge (75,000 kWh @ RM0.365)RM 27375.00
Maximum Demand (950 kW @ RM41.60/kW)RM 39520.00
Solar self-consumption savings (20,000 kWh)-RM 7300.00
Service ChargeRM 7.20
KWTBBRM 273.75
Net savings from peak shavingRM 6180.00
TotalRM 72240.00

12-Month Performance

Jan
RM 76890
RM 70120
32500 kWh
Feb
RM 77450
RM 71080
31800 kWh
Mar
RM 78120
RM 71950
33200 kWh
Apr
RM 79200
RM 72890
32900 kWh
May
RM 79850
RM 73560
33400 kWh
Jun
RM 80100
RM 73920
33650 kWh
Jul
RM 79650
RM 73480
33500 kWh
Aug
RM 78890
RM 72720
33300 kWh
Sep
RM 77980
RM 71890
32800 kWh
Oct
RM 76920
RM 70950
32100 kWh
Nov
RM 75680
RM 69870
30900 kWh
Dec
RM 74790
RM 69050
31200 kWh
Before Solar
After Solar

“The peak shaving system from Trexon transformed our cost structure. RM6,180/month in direct savings, but the real win is competitive pricing—we can now bid 5% lower than competitors still on full grid. The GITA tax benefit was RM360k—that alone justified the investment.”

Dato' Tan Chee Keong

Managing Director, Penang Assembly Solutions

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