Major Manufacturing Facility | Plymouth, Devon | 1.6MW Solar PV Installation Across Two Sites
1.6MW Solar PV | 3,555 Solar Panels | Two Manufacturing Sites | 24/7 Industrial Operations | Electricity Cost: 26p/kWh
When a manufacturing business operates 24 hours a day, 365 days a year, electricity isn't simply another overhead. It's a fundamental part of production, and every kilowatt-hour purchased from the grid directly affects profitability.
For a major manufacturing facility in Plymouth, the challenge was clear: how could the business reduce its substantial electricity costs without compromising continuous production?
The solution was a 1.6MW commercial solar PV installation, consisting of approximately 3,555 solar panels across two sites, designed to generate significant amounts of renewable electricity and reduce the cost of operating the factories.
The Challenge – A Factory That Never Stops
Unlike a typical commercial building, where electricity demand falls considerably outside working hours, this manufacturing operation required substantial electrical power around the clock.
Production machinery, processing equipment, ventilation, lighting and supporting infrastructure all contributed to the facility's considerable electricity consumption.
With manufacturing operating continuously throughout the year, electricity represented a significant and unavoidable business expense.
At an electricity cost of 26p per kWh, every unit of solar electricity generated and consumed on-site represents a direct saving of 26p in purchased electricity.
The Solution – 1.6MW of Solar Generation Across Two Sites
The project involved installing approximately 3,555 solar panels, providing a combined generation capacity of 1.6MWp.
By distributing the installation across two manufacturing sites, the project maximised the available space for renewable electricity generation while supporting the substantial daytime electrical demand of the business.
The installation was designed to:
- Reduce purchased electricity: Generate electricity directly at the manufacturing facilities.
- Support continuous production: Offset electricity consumed by industrial machinery and processing equipment.
- Reduce operating costs: Lower the amount spent on grid electricity.
- Improve manufacturing profitability: Convert electricity savings into reduced production overheads.
- Support sustainability objectives: Reduce reliance on grid-supplied electricity and associated carbon emissions.
Attention to Detail – Built for Long-Term Reliability
With more than 3,500 solar panels installed across two sites, attention to detail was an essential part of delivering a reliable, long-lasting installation.
One example of this approach was the care taken with the solar panel mounting system.
Every single end clamp was individually marked with a permanent pen following installation and tightening.
These witness marks provide a clear visual reference, allowing maintenance engineers to identify potential movement or rotation of the clamps during future inspections.
Although the marks do not physically prevent movement or replace the manufacturer's specified tightening requirements, they provide a valuable additional visual check.
On an installation of this scale, even the smallest details matter. Ensuring that mounting components are correctly installed, tightened and readily inspectable helps protect the integrity of the entire solar array.
It's this attention to detail, from the largest electrical components down to individual panel clamps, that reflects Callidus Trade's commitment to quality engineering and long-term system reliability.
Why Solar Works for Energy-Intensive Manufacturing
One of the major advantages of installing solar at a large manufacturing facility is the opportunity to use a high proportion of the electricity generated directly on-site.
Because the factories operate continuously, there is substantial underlying electrical demand during daylight hours when the solar panels are producing energy.
This creates an opportunity to maximise the financial value of solar generation by reducing grid electricity purchases rather than relying primarily on exporting surplus electricity.
Although solar generation naturally varies throughout the day and year, every unit consumed on-site contributes directly to reducing the facility's electricity expenditure.
Every Kilowatt-Hour Saved Is Increased Profit
For manufacturing businesses, energy efficiency is directly linked to financial performance.
Reducing electricity costs improves operating margins without requiring the business to manufacture more products, recruit additional staff or increase sales.
At an electricity purchase price of 26p per kWh, the financial benefits are substantial:
| Solar electricity consumed on-site | Electricity cost saving |
|---|---|
| 100,000kWh | £26,000 |
| 500,000kWh | £130,000 |
| 1,000,000kWh | £260,000 |
| 1,200,000kWh | £312,000 |
| 1,400,000kWh | £364,000 |
| 1,600,000kWh | £416,000 |
These are illustrative savings at 26p/kWh, rather than measured generation figures. Actual savings depend on annual PV generation and the proportion consumed directly on-site.
Long-Term Protection Against Rising Energy Costs
Industrial electricity prices can have a significant impact on competitiveness, particularly for energy-intensive manufacturers.
By producing a significant proportion of its electricity requirements on-site, the business reduces its exposure to purchased electricity prices.
With each kilowatt-hour of self-consumed solar generation worth approximately 26p in avoided electricity purchases, the long-term financial benefits can be substantial.
Unlike many other business investments, reducing energy expenditure can improve profitability directly without increasing production volumes.
System Specifications
- Project: Large-scale industrial solar PV installation
- Location: Plymouth, Devon
- Industry: Manufacturing
- Total solar PV capacity: 1.6MWp
- Solar panel quantity: Approximately 3,555
- Number of sites: Two
- Operational demand: Continuous, 24 hours a day, 365 days a year
- Electricity cost assumption: 26p/kWh
- Mounting quality control: Individual end-clamp witness marking using permanent pen
- Primary application: Industrial machinery, manufacturing processes and general site electricity consumption
- Primary objective: Reduce grid electricity purchases and improve operating profitability
- Additional benefit: Reduced reliance on grid-supplied electricity
Powering Manufacturing Profitability Through Solar
This project demonstrates the commercial value of renewable electricity generation for energy-intensive manufacturing businesses.
With 1.6MW of solar PV installed across two sites, the business can generate substantial amounts of its own electricity, reducing the cost of powering its manufacturing operations.
At an electricity price of 26p per kWh, every million kilowatt-hours of solar electricity consumed on-site represents £260,000 in avoided annual electricity purchases.
However, delivering a successful commercial solar installation isn't simply about the number of panels or the amount of electricity generated. It's also about the standard of engineering, installation quality and attention to detail that ensures the system remains reliable for decades.
3,555 solar panels. 1.6MW of generating capacity. Two manufacturing sites. Every end clamp individually marked and checked. One objective – reliable renewable energy that reduces operating costs and increases profitability.
