EMPOWER Spotlight – Hypertherm

Hypertherm's Solaflect off-grid EV chargers in action. Photo: Seven Days VT

Key Facts

Workplace Location: Hanover, New Hampshire

Workplace Size: 1200+ employees across 10 facilities in Hanover, NH.

Type of Workplace: Employee-owned industrial cutting technology producer.

Charger Details: Seven grid-tied Level 2 chargers and two off-grid Apollo chargers across ten facilities.

Program Details:

• All chargers were installed over a nine-year period, beginning in 2016.

• Initial installations were driven by efforts to reduce emissions from employee commutes.

• In 2024, Hypertherm began leasing two off-grid solar EV chargers from Solaflect Energy to increase charging capacity without increasing electrical load. Each Apollo EV charger has the capacity to charge four EVs at a time.

• Charging is free and available whenever Hypertherm associates are at work to help combat range anxiety.

• Hypertherm developed a digital message board to manage EV charger scheduling.

  
  

Organization Background

Hypertherm is an employee-owned company that provides industrial cutting technologies and solutions. Its mission is to deliver shared value for people and the planet, alongside profitability. To guide its environmental stewardship efforts, Hypertherm established ambitious 2030 goals: achieve carbon-neutral operations, eliminate 50% of waste, reduce customer carbon emissions by 50%, and improve their Circulytics circular economy score to a B.

Solaflect Energy is a Vermont-based renewable energy company that designs, manufactures and installs the innovative Apollo, an off-grid, 100% solar-powered EV charging solution that sets a new standard for sustainability and affordability in EV charging. Particularly well-suited for workplace EV charging, Apollo follows the sun, providing ample EV charging for multiple EVs/plug-in hybrids with 100% clean, solar energy. With a commitment to sustainability, the company has spent 18 years contributing to the global fight against climate change by making clean energy broadly accessible.

Program Evolution and Growth

In 2010, Hypertherm formalized environmental stewardship as a corporate value and began identifying the company’s carbon impacts. An internal study found that many employees commuted long distances alone from across New Hampshire and Vermont, significantly contributing to the company’s carbon footprint. To address this, Hypertherm introduced financial incentives for carpooling, public transportation, biking, and walking. As electric and hybrid vehicles became more common, the company added a one-time financial incentive for employees purchasing a green vehicle, based on the U.S. Environmental Protection Agency’s Green Vehicle Guide.

When employees began to express concerns about range anxiety, Hypertherm installed wall-mounted Level 2 chargers across their New Hampshire facilities. These chargers were intended for use only by employees experiencing range anxiety and were subject to a four-hour charging limit. Hypertherm also developed a custom app that allows employees to sign in when they begin charging, view charger availability, and support enforcement of the time limit.

 As Hypertherm explored new EV charging solutions, they were introduced to Solaflect through their respective Clean Cities and Communities Coalitions at a local regional event. Then in September 2024, Hypertherm increased charging capacity by leasing two Apollo solar-powered EV chargers from Solaflect. Apollo chargers are off-grid technologies that can charge up to four vehicles at a time. The solar array accurately follows the sun which allows it to generate 40% more energy than a comparable fixed array. Each Apollo EV charging unit is designed for flexibility, allowing it to fit within existing parking configurations and enabling quick installation.

For industrial facilities like Hypertherm, where electrical loads are already tightly managed, minimizing additional demand is critical. Energy and facilities managers have expressed a strong preference for off-grid chargers, which are maintained by Solaflect, and help avoid further strain on the facility’s grid infrastructure. While the power output of the Apollo chargers varies with weather conditions, employees have found that they consistently provide sufficient power to alleviate range anxiety, even on cloudy days. Hypertherm’s app includes a pop-up message feature that allows the company to reinforce the policy of using solar chargers first, especially on sunny days. Employees also use a digital message board to share real-time updates on charging performance under different weather conditions and times of day. Solaflect staff monitor the board and respond directly to employee questions, helping build confidence in the reliability of solar charging.

Best Practices and Lessons Learned

Hypertherm’s workplace charging strategy reflects a thoughtful balance between operational needs and employee access. From the beginning of the workplace charging program, the company limited use of EV chargers to employees experiencing self-reported range anxiety to manage demand. However, range anxiety has proven difficult to define and enforce consistently. To better understand employee needs and refine this policy, Hypertherm developed and distributed an internal survey and the results revealed that perceived range anxiety fluctuates with factors such as cold weather, early or late shifts, and the need to run errands after work.

To expand access while minimizing load impacts, Hypertherm leased solar-powered Apollo chargers from Solaflect. Employees are now required to use these chargers first before plugging into grid-tied chargers to reduce strain on the facilities’ electrical system. The custom-built app and message board helps Hypertherm and Solaflect maintain the workplace charging program and fosters open discussion around potential updates and expansion areas. Together, these strategies highlight the value of flexible infrastructure, clear communication, and non-grid-tied solutions in supporting resilient workplace charging.