Exeter Miniskips (EMS) | Exeter, Devon | 200kW Commercial Solar PV Installation

200kW Solar PV | Three-Phase Integration | Combined Heat and Power (CHP) | 4.6-Year Payback | 21.7% Estimated Annual ROI

How do you power a large, energy-intensive recycling facility while keeping electricity costs under control?

For Exeter Miniskips (EMS), a large and growing waste management and recycling company based in Exeter, the answer was to bring three electricity sources together: solar PV, combined heat and power (CHP), and the National Grid.

The result was a 200kW commercial solar installation designed to work alongside the site's existing CHP energy generation, helping provide the substantial electricity required for industrial recycling machinery and waste recovery operations.

The Challenge – Recycling Waste Requires Significant Energy

Operating a large commercial recycling facility involves much more than collecting and sorting waste.

Heavy-duty processing machinery, conveyors, separation equipment and material handling systems all require substantial amounts of electricity to recover valuable resources and turn waste into reusable and recyclable products.

EMS already benefited from a CHP system acting as an on-site energy provider, generating electricity and useful heat to support operations.

However, the CHP system alone did not eliminate the need for additional electricity. With growing operational demands and energy-intensive equipment, the business required further generation capacity.

The challenge was to introduce a major solar installation that could operate alongside the CHP system and the existing three-phase grid supply without disrupting the facility's daily operations.

The Solution – Three Power Sources Working in Harmony

Callidus was commissioned to deliver a 200kWp rooftop solar PV installation on the facility's existing trapezoidal metal roof.

The system was integrated with the existing CHP electricity generation and the National Grid, allowing all three energy sources to contribute to the site's electrical requirements.

• 200kW solar PV: Generating renewable electricity during daylight hours to power industrial machinery and reduce grid consumption.
• Existing CHP energy provider: Supplying on-site generated electricity and useful heat to support the recycling facility's operations.
• National Grid: Providing additional electricity whenever the combined on-site generation is insufficient to meet the facility's demand.

The integration of these three power sources allowed EMS to maximise the benefits of its existing CHP investment while introducing substantial additional renewable generation.

Designed for Energy-Intensive Industrial Operations

The installation was designed to offset electricity consumed by:

• Industrial waste processing and recycling machinery
• Conveyors and material separation equipment
• Mechanical handling and material recovery operations
• General industrial electrical services
• Lighting, offices and supporting infrastructure

The combination of CHP and solar power provides complementary generation, helping meet significant daytime electrical demand and reducing the electricity required from the grid.

Strong Financial Returns – A Payback of Just 4.6 Years

With an estimated payback period of 4.6 years, the solar installation represents an annual simple return on investment of approximately 21.7%.

Financial highlights

• 21.7% estimated annual simple ROI
• 4.6-year estimated payback period
• 217% gross cumulative return over 10 years
• 117% net cumulative ROI over 10 years
• 435% gross cumulative return over 20 years
• 335% net cumulative ROI over 20 years
• Reduced dependence on purchased grid electricity
• Improved utilisation of existing CHP generation alongside solar PV

These are simplified projections based on consistent annual financial savings, before maintenance, degradation, financing and other costs.

System Specifications

• Client: Exeter Miniskips (EMS)
• Location: Exeter, Devon
• Solar PV capacity: 200kWp
• Roof construction: Trapezoidal metal roof
• Electrical connection: Three-phase
• Existing energy provider: CHP boiler and electricity generation system
• Integrated electricity sources: Solar PV, CHP and National Grid
• Primary application: Industrial recycling and waste recovery
• Estimated annual simple ROI: 21.7%
• Estimated payback: 4.6 years
• Project objective: Support industrial energy demand while reducing purchased electricity

Three Energy Sources – One Integrated Solution

The EMS project is a powerful example of how different energy technologies can operate together to meet the substantial electricity demands of modern industry.

Rather than replacing the existing CHP system, the solar installation was designed to complement it, allowing EMS to benefit from both established on- site electricity generation and additional renewable power.

The CHP generates energy. The solar reduces purchased electricity. The grid provides additional supply when required. Together, they help power an energy-intensive recycling operation.

With an estimated 21.7% annual return and a payback of just 4.6 years, the installation demonstrates the commercial value of intelligently integrating multiple energy sources.

Callidus Trade – Engineered Energy Solutions for Demanding Industrial Applications.