Greater efficiency through intelligent electrical planning

The project was prompted by a fire that forced the long-established bakery to temporarily distribute its production activities across several locations. The new building will allow Böhli AG to bring production, storage and sales back together under one roof. This will not only shorten distances and streamline processes but also provide an opportunity to design an energy supply system that is ready for the future.
Bühler + Scherler is supporting this ambitious project from the initial needs assessment through to commissioning, final acceptance and handover to the client. Our contribution includes comprehensive electrical planning, a photovoltaic system with battery storage, and an intelligent energy management system.

Bühler + Scherler was awarded the planning contract for the new production facility in October 2025, with the first work beginning just two months later. Together with the client, we analyzed the company’s operational requirements, defined the project objectives and developed several concept options based on the findings.

The project is currently in the detailed design phase. On site, the electrical contractor is using our plans to install the required conduits and components in the floor slabs and walls. The new production facility is scheduled to be commissioned in the first quarter of 2027.


Accurate system sizing based on reliable data

A detailed survey of the existing production facilities provided an important basis for the planning process. We documented both the existing systems and the operational workflows. This ensures that the new facility will at least meet the current standard while also enabling targeted improvements.

In addition, we analyzed the electrical load profiles of the existing operations. This allowed us to determine the grid connection capacity in line with actual requirements. By avoiding unnecessary oversizing, we can also prevent excessive investment and connection costs.


Generating and using solar power on site

One of the client’s key objectives is to use as much of the solar power generated on site as possible within its own operations. The primary focus is on optimizing ongoing production: energy should ideally be available precisely when it is needed. This reduces both the amount of electricity drawn from the grid and the associated costs.

A photovoltaic system with battery storage is therefore a central element of the energy concept. The photovoltaic modules will be installed not only on the roof but also on the building’s east-, west- and south-facing façades. This distributes electricity generation more evenly throughout the day. The façade-mounted modules can also generate energy during the winter, when the sun is lower in the sky or the roof is temporarily covered with snow.

To ensure that the solution is not only technically effective but also economically viable, our team calculated the levelized cost of electricity and provided a transparent overview of the expected savings and potential additional revenue opportunities. Based on the current planning assumptions, the complete system comprising photovoltaics, battery storage and energy management is expected to achieve a payback period of approximately 15 years. Once the facility is operational, the interaction between the individual systems can be further optimized using real-world operating data. If additional optimization potential is realized, the expected payback period could be reduced to approximately ten to fifteen years.

The modular battery storage system will use lithium iron phosphate (LFP) batteries. This technology combines high storage capacity in a relatively compact space with an exceptionally high level of safety. Thanks to their high thermal stability, LFP cells are less susceptible to overheating in the event of a fault than other lithium-ion technologies.

Another important advantage is their long service life: the storage system is designed to last up to 10,000 charging cycles. The technology also supports high charging and discharging rates, allowing energy to be stored quickly and made available again just as rapidly when required.

Despite the high level of safety offered by the selected cell technology, installing the battery system inside the building presents specific fire protection requirements. The system was therefore planned in close consultation with the responsible fire safety specialist. In the event of an emergency, the fire service must be able to flood the battery room from outside without requiring emergency personnel to enter it.

Flexibility is also a key consideration in the system’s design. During the first phase, the storage system will be installed with around two-thirds of the planned capacity and one-third of the maximum possible power output. This keeps the initial investment manageable without limiting future expansion options. After commissioning, the system can be further optimized using real operating data and expanded with minimal effort if required without interrupting ongoing production.


Energy management reduces peak demand

Our analysis of the existing load profiles clearly showed that demand peaks have a significant impact on grid usage charges. To reduce these peaks systematically, we are planning an energy management system (EMS) with integrated load management.

Meters continuously record the relevant energy flows. Based on this data, the EMS coordinates the connected equipment and the battery storage system via a range of interfaces. It smooths the load profile, reduces demand peaks and therefore helps lower grid usage costs in the long term. At the same time, the system ensures that as much of the solar power generated on site as possible is used directly within the facility. This improves the overall energy efficiency of the production site, aligning economic and environmental objectives.

Solutions of this kind are particularly attractive for businesses whose energy consumption is characterized by high demand peaks. By systematically smoothing these peaks, they can reduce their grid usage costs.

There is also significant potential for businesses with large photovoltaic systems that occasionally generate more electricity than can be consumed immediately. Instead of feeding all of this surplus power back into the grid, some of it can be stored in the battery system and used later, for example, to supply the facility at night. Whether such a solution is economically viable, and how it should be sized, must be assessed based on the company’s individual consumption and generation profiles.
 

Precise planning for efficient implementation

To support efficient implementation, our team prepares detailed plans and schematics. Three-dimensional coordination with the specialists responsible for heating, ventilation, air conditioning and sanitary systems helps identify potential clashes at an early stage and avoid additional costs.

Bühler + Scherler will also remain closely involved throughout the construction phase. Our on-site engineering team coordinates the work, monitors deadlines and continuously checks the quality of the electrical installations. Ongoing cost monitoring provides additional transparency and gives the client greater cost certainty.


Support beyond project completion

Our involvement does not end when construction is completed. As part of an ongoing consulting and optimization mandate, we will continue to support the client during operation. The collected energy and operating data will allow the systems to be progressively refined, helping ensure that they remain as efficient and cost-effective as possible over the long term.
With its new production facility, Böhli bakery is laying the foundations for more efficient processes, a reliable energy supply and continued growth. We are proud to contribute our electrical and energy planning expertise to this forward-looking project.