Accelerating production of commercial HVAC supply-duct thermal storage system
Low-rate initial production line to increase manufacturing of innovative new thermal energy storage system that can be easily added to any existing HVAC system to dramatically reduce late-day peak air conditioning energy demand, statewide.
Stasis Energy Group LLC
Recipient
Rancho Cucamonga, CA
Recipient Location
29th
Senate District
50th
Assembly District
$27,848
Amount Spent
Active
Project Status
Project Update
Stasis Energy Group has made steady progress in 2025 toward its low-rate initial production (LRIP) target of 60 panels per hour through targeted process improvements and ongoing workforce training. A major milestone was the delivery and commissioning of a proprietary ultrasonic welding system, purpose-built to support LRIP throughput and to produce a hermetically sealed weld on thin aluminum. This weld encapsulates an organic, bio-based phase change material that enhances energy efficiency, reduces late-day electrical demand, shifts load from peak to off-peak hours, and significantly lowers greenhouse gas emissions associated with HVAC systems. Following initial commissioning, further refinements were made to the welding process, resulting in seals that are consistent, mechanically robust, and capable of withstanding ASTM E84 fire testing requirements. As these process improvements and training efforts have matured, production error rates have decreased substantially, while overall throughput continues to trend upward. Looking ahead to 2026, Stasis Energy Group plans to transition manufacturing to a larger, integrated facility that will co-locate office and production operations. This expansion is expected to increase production capacity while strengthening cross-functional communication and coordination, further supporting scalable manufacturing and operational efficiency.
Stasis Energy Group has kicked off this project in 2024. This RAMP agreement is designed to deliver increased manufacturing capabilities of our novel thermal storage system. A new shop location has been identified, and final site selection is down to five candidates. The Stasis team will finalize site location by mid-Q1 2025. The design for the new welder has also been finalized, and equipment contracts are finalized. Improvements expected in the new technology are significant and will result in an increased rate of performance, reduction in error rates and improvement in quality. Work has been done developing standard processes and documentation to support future manufacturing as well as setting the foundation for bringing in new members as we expand.
The Issue
In order to make an impact on the California grid, enough thermal storage systems must be produced and installed across the state to make a meaningful impact on peak demand from HVAC. The main issue is that Stasis's manufacturing capabilities before the RAMP grant did not support this goal. The manufacturing shop was only able to support a single unit being produced each day, which would take decades of manufacturing before the benefit of the technology was fully realized statewide. With the RAMP grant supporting LRIP, Stasis Energy Group will be able to produce about 10 units in a single shift, or 30 units over the course of a day. This allows Stasis to move forward with installations at a significantly increased pace and deliver the biggest benefit as quickly as possible.
Project Innovation
This Project will expand the manufacturing capabilities of the recipient's novel Thermal Energy Storage System (TESS) through the creation of a Low-Rate Initial Production (LRIP) line. This innovative new technology can be easily added to any existing HVAC system to dramatically reduce late-day peak air conditioning energy demand, statewide. The LRIP line will advance the current manufacturing processes by replacing rudimentary hand operated processes with refined machine operated processes, which will increase production quantity and quality and bring the technology closer to market.
Project Goals
Project Benefits
The project allows for the increased production of thermal storage systems, which allows more people to participate in load flexibility, reduce grid stress, increase daily capacity to capture and store more sustainable energy, and lower traditional carbon-fueled electricity use as well as reducing GHG emissions related to HVAC by as much as 80%.
Affordability
SEG's focus on deployment in disadvantaged communities and tribal sites supports the company’s key equity goals by lowering peak energy costs at every site.
Safety
This Agreement will result in a safer method of energy storage than traditional electrochemical batteries because it is not subject to thermal runaway or dangerous off gassing, and the TESS is fire rated for plenum applications. Furthermore, there is much less environmental impact than traditional batteries. TESS does not pose end of life concerns and is 100% recyclable.
Key Project Members
Rob Morton
Dr. Seth Miller PhD
Victoria Luna
Match Partners
Stasis Energy Group LLC
PureTemp LLC
