23.6.2025

Megawatts instead of kilowatts: how a charging park with battery storage and load management became an e-truck hub

After more than 1.5 years of planning, it is now up and running: the new AVIA VOLT charging park in Dierikon (LU) - equipped with a 1 MWh/1 MW battery storage system, three fast-charging stations with 360 kW charging power each and an intelligent energy management system from CLEMAP. A practical example that shows: With a well thought-out system design, many electric vehicles, whether cars or trucks, can be charged efficiently even without grid reinforcement.

The initial situation: grid limit reached - and the e-trucks are coming

At the beginning of the project, Schätzle AG, the operator of the AVIA filling station in Dierikon, faced a challenge: the decision had been made to expand the site with a charging park, the fast-charging stations had been ordered - but the existing grid connection only offered 100 kW. A classic dilemma: electrification yes - but how if the grid is limited?

AVIA VOLT Suisse, the AVIA competence center for electromobility, develops practical charging infrastructure solutions for public charging and especially for heavy goods vehicles - with a focus on scalability, efficiency and intelligent energy systems.

The central question for CLEMAP: How can several electric vehicles be charged at the same time - with the support of photovoltaics and battery storage?

The idea: battery storage instead of grid expansion

After a joint analysis phase, it was clear that a large battery storage system (BESS) combined with an intelligent load management system is a more economical, faster and scalable solution. Because:

  • During the day, the storage unit is charged, e.g. with PV electricity or favorable grid times.
  • Unloading takes place when necessary - for example, if several trucks want to load at the same time.
  • The grid is relieved and the charging time is massively reduced.

This is how the project became a reality - with an ambitious goal: ultra-fast charging without expanding the grid.

The building: from idea to reality

The project presented CLEMAP with a number of challenges: The battery storage system was manufactured in China - including assembly and initial testing in the winter of 2024/25. CLEMAP sent a load management device to China in advance to test communication with the storage system on site. This was already exciting: Will the device really arrive? Does everything work as planned?

The system was intensively tested at the Chinese production facility together with the battery manufacturer's engineering team, AVIA VOLT and CLEMAP. The collaboration took place via WeChat - which was also a new experience for everyone involved. The shipping of the container in February/March 2025 was an important milestone: by then, all interfaces had to work and the communication between the battery and CLEMAP load management had to be fully tested.

The project also broke new ground in Switzerland: for the first time, CLEMAP was not only able to measure with a solar inverter, but also actively control via the Solar-Log when PV electricity flows into the battery or is fed back into the grid - a major step towards optimizing self-consumption. A solar inverter converts the direct current generated by the PV system into alternating current and enables the targeted control of self-consumption and grid feed-in. At the same time, it had to be ensured that the main connection box (MCC) was not overloaded when feeding power back into the grid. The control system therefore not only had to be efficient, but also safe - and it is.

We are proud of the fantastic collaboration within our CLEMAP Tech team: the coordination between the individual areas was challenging and required a lot of coordination - from load management to battery integration and PV connection. Thank you all!

Sandro was primarily responsible for the project and was in close contact with the battery manufacturer in China.‍

Raffael took care of the integration of the solar inverter - a first in CLEMAP projects, where it was possible to actively influence the feed-in for the first time.

Fabian was responsible for the implementation and fine-tuning of the load management system - from integration to practical configuration on site. A load management system intelligently distributes the available electrical power to several consumers - in this case to the charging points - and ensures that grid connections are not overloaded, charging processes are prioritized and energy is used optimally.

Implementation at the Dierikon (LU) site began in spring 2025. From site marking, earthworks, cable routes and foundations to the final placement of the battery storage system - everything was carried out in close cooperation with the local construction partners.

Pictures impressively document how a filling station area was transformed into a modern charging park with AVIA VOLT battery storage, red and white marked fast-charging zones and clearly structured charging infrastructure.

Test day and commissioning with a signal effect

On 16.06.2025, the time had come: during the successful C-Booster test day on site, the entire system was put through its paces - under real conditions.

The charging park has officially been in operation since Monday, 16.06.2025- a moment we have been working towards together for a long time.

The inauguration with invited guests is planned for August. Until the end of September, customers can charge with the AVIA VOLT card or by credit card at the special rate of 50Rp./kWh.

Facts and figures

The results in Dierikon speak for themselves: the combination of CLEMAP load management and battery storage enables fast and efficient charging - even with a limited grid connection.

The result in operation:

  • 🚚 Six e-trucks can be charged at the same time
  • 1.3 hours charging time for an electric truck with BESS (instead of 8.5 hours without)
  • 🏗️ No additional grid expansion necessary
  • 📊 Real-time monitoring and control via the CLEMAP dashboard

The technical equipment of the charging park also shows how scalable and practical the solution is:

The facility in Dierikon today comprises:

  1. 1 MW / 1 MWh battery storage system
  2. 3 × Kostad DC fast charging stations with 360 kW power each
  3. 🅿️ 6 loading bays
  4. 🧠 CLEMAP energy management system for dynamic control and optimization

"After more than 1.5 years of meticulous planning, our battery storage facility with charging infrastructure is finally up and running. The project in Dierikon is a major milestone for AVIA VOLT and a real step forward for sustainable energy systems in heavy goods vehicles."
- Daniel Spiri, Large Battery Product Manager and HPC Project Manager, AVIA VOLT

More than just peak shaving

The battery storage system used is more than just an electricity buffer - it fulfills several functions at the same time:

  • 📉 Peak shaving: Peak loads are smoothed - and thus reduce grid usage costs.
  • EV Boosting: Accelerated charging, even with a weak mains connection.
  • 💰 Tariff optimization: Charge when electricity is cheap - discharge when it's expensive.
  • ☀️ PV integration: Use surpluses on site instead of feeding them into the grid.
  • 🔄 Balancing energy readiness: With an appropriate connection, the storage system could provide secondary grid services such as balancing energy - and thus generate additional income.
  • Control is automatic via the CLEMAP energy management system, which prioritizes AC and DC charging stations in real time and takes dynamic tariffs into account.

    Why this is crucial right now

  • Battery storage systems are becoming increasingly affordable - prices have fallen by around 90% since 2010. At the same time, demand is rising rapidly: in Germany alone, over 226 GW of connection applications for storage systems have been reported. Photovoltaic electricity is also not yet being used efficiently in many places - CLEMAP helps to better integrate this locally. And last but not least, more and more companies are relying on electric trucks, which require an efficient charging infrastructure. Solutions are needed that work quickly, reliably and economically - like in Dierikon.
  • Conclusion: The solution is here - scalable and ready

    The example of Dierikon proves this: The combination of CLEMAP load management and battery storage enables ultra-fast, grid-friendly charging for e-trucks - now and without waiting for grid expansion. Scalable, economical, future-proof.

    Are you interested?

    Do you operate a charging park or are you electrifying your logistics fleet? Would you like to know how peak shaving works for you? Arrange a consultation with CLEMAP now and make your site fit for megawatt charging:

    Festim Zeneli, festim.zeneli@clemap.com, +41 44 518 01 28

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