Deliverable 4.1, Characterisation of demo sites, was developed by STAM within the JOULIA project as part of Work Package 4. It establishes the technical and operational baseline needed to support the design and deployment of JOULIA’s innovative induction and microwave heating solutions for industrial processes.
The main objective of D4.1 is to build a detailed understanding of the two industrial demonstration sites involved in the project by characterising the targeted production processes, mapping material and energy flows, and identifying data gaps that must be addressed to enable effective electrification, flexibility, and system optimisation.
From process characterisation to market context
The deliverable is structured around three main pillars. First, it outlines the scope, objectives, methodology, and links with other JOULIA activities. Second, it provides an in depth characterisation of the two industrial demonstrators. Third, it analyses the European energy and ancillary services markets to assess how electrified industrial processes can generate additional value through flexibility.
Task 4.1 focused on collecting detailed technical, energy, and operational data from both demo sites. This was achieved through structured questionnaires, direct collaboration with demo leaders, on site visits, and a comprehensive market analysis aligned with European standards and regulations. Together, these activities provide a robust baseline for subsequent design, digitalisation, and exploitation work within the project.
Industrial demo sites at the core of JOULIA
At Artigo in Italy, the report focuses on rubber flooring vulcanisation, a continuous and energy intensive process carried out using a rotocure machine. The process currently relies on diathermic oil heating, with different machine components operating at temperatures ranging from around 100oC to over 200oC, depending on product thickness. The site already benefits from a detailed monitoring system that records key process parameters such as temperatures, pressures, valve positions, and production speed.
At KFLEX in Poland, the focus is on glue thermal activation in the production of multilayer plastic insulation pipes. This process requires continuous heating up to 100oC and is currently performed using an electric induction system. The site has a high electricity demand and is gradually increasing its on site renewable energy capacity. While energy monitoring is currently performed mainly at plant or line level, plans are in place to introduce more granular, component level measurements.
Understanding flexibility and market opportunities
Beyond process characterisation, D4.1 provides a clear overview of how European wholesale and balancing markets operate, from long term planning to real time operation. Particular attention is given to balancing services such as Frequency Containment Reserve, automatic Frequency Restoration Reserve, and manual Frequency Restoration Reserve, which are gradually opening to demand side flexibility and distributed energy resources.
The analysis highlights that Italy and Poland broadly align with European frameworks, although participation of industrial demand and aggregators remains limited. Germany is presented as a reference case for more mature and inclusive market structures that actively support aggregation and flexibility.
While the industrial processes addressed by JOULIA require stable and continuous heat profiles, the report shows that coupling electrified processes with on site generation and energy storage can unlock flexibility and new revenue opportunities without disrupting production. A reference use case is therefore proposed, based on optimised scheduling of distributed generation, storage, and limited demand flexibility to reduce energy costs and access balancing markets when economically favourable.
Overall, Deliverable D4.1 provides a solid foundation for the next stages of the JOULIA project. Its results directly support the design and engineering of the induction system for rubber vulcanisation, the microwave system for glue activation, and the development of digital tools for process optimisation and flexibility management.
The full Deliverable D4.1 is available for download in the Deliverables section of the website and offers detailed technical insights for industry stakeholders interested in electrification, flexibility, and the future role of industrial processes in Europe’s energy system.
