Project Overview
Energy Gain was appointed to design and install a 520kWp commercial rooftop solar PV system at J Banks & Co. Ltd’s manufacturing facility in Staffordshire. The project was designed to reduce the site’s reliance on grid electricity, lower operational carbon emissions and support J Banks’ long-term sustainability strategy.
As a leading UK manufacturer of architectural ironmongery, door hardware and access control products, J Banks operates a high-energy manufacturing facility with significant daytime electricity demand. This made the site an ideal candidate for solar panels for manufacturing facilities, allowing renewable electricity to be generated onsite and used directly within the manufacturing process.
The installation demonstrates how manufacturing solar panels and commercial solar PV solutions can help industrial businesses reduce energy costs, improve energy security and make progress towards their sustainability objectives.
The Challenge
Although the site offered excellent solar generation potential, the installation required careful engineering and project management to ensure manufacturing operations continued without interruption.
Maintaining Manufacturing Operations
J Banks continued normal production throughout the installation. Manufacturing schedules, vehicle movements and staff access all had to be maintained, making health and safety and operational continuity the highest priorities.
The client required the installation to be completed with minimal disruption to production, ensuring manufacturing output was not affected.
Large Industrial Roof Design
The manufacturing facility provided significant roof space suitable for solar PV. However, before installation, detailed structural assessments were required to verify roof loading capacity and determine the most appropriate mounting solution.
The design also needed to maximise generation while accommodating rooflights, ventilation equipment and maintenance access routes.
Working Within an Active Industrial Environment
The site experienced constant movement of heavy goods vehicles, forklifts and operational staff. Installation activities had to be carefully coordinated to maintain safe segregation between construction works and daily manufacturing operations.
Coordinated Material Deliveries
Installing a 520kWp solar PV system required the phased delivery of solar panels, mounting systems, inverters and electrical equipment. Deliveries were carefully scheduled to reduce on-site storage requirements and minimise disruption to the client’s logistics operations.
Our Solution
Energy Gain worked closely with J Banks to design and deliver a bespoke commercial solar installation for a manufacturing facility, tailored around the site’s operational requirements.
Following detailed surveys and engineering assessments, Energy Gain developed a solar PV system that maximised available roof space while considering structural requirements, electrical infrastructure, inverter positioning and future maintenance access.
The completed 520kWp rooftop solar PV system provides J Banks with a reliable source of renewable electricity generated directly at their manufacturing site. By installing solar panels across the facility, the business can reduce imported grid electricity, lower operational costs and support its wider environmental goals.
The project highlights how solar panel installations for manufacturing businesses can deliver both financial and sustainability benefits when carefully designed around the needs of an operational industrial facility.
Project Results
The 520kWp commercial rooftop solar PV system is expected to generate approximately 382.72MWh (382,720kWh) of renewable electricity each year, saving around 78 tonnes of CO₂ annually. Over its operational lifetime, the system is forecast to generate approximately 8,975 MWh of clean electricity, delivering significant long-term environmental and financial benefits for the business.
Project Statistics
- System Size: 520kWp
- Solar Panels Installed: 1040
- Annual Generation: 382.72 MWh
- Annual CO₂ Savings: 78 Tonnes
- Lifetime CO₂ Savings: 1858 Tonnes
Engineering Insight
Manufacturing facilities present unique opportunities for commercial solar because they typically have high daytime electricity consumption that closely aligns with peak solar generation.
Before installation, Energy Gain completed a full structural assessment of the building to verify roof suitability and determine the optimum mounting solution.
The system was engineered to:
- Maximise available roof space
- Optimise annual electricity generation
- Maintain safe roof access for future maintenance
- Integrate efficiently with the existing electrical infrastructure
- Minimise electrical losses through optimised inverter and cable design
Careful consideration was also given to cable routing, inverter positioning, system monitoring and future maintenance requirements to ensure long-term reliability and performance.
The completed installation provides J Banks with a dependable source of renewable electricity while reducing reliance on the National Grid during operating hours.
Why Solar is Ideal for Manufacturing Facilities
Manufacturing businesses are among the strongest candidates for commercial solar due to their high and consistent electricity consumption during operational hours.
Production machinery, manufacturing equipment, warehouse operations and lighting systems typically require significant amounts of electricity throughout the working day. This aligns closely with solar generation periods, allowing businesses to maximise the use of renewable electricity generated onsite.
Installing solar panels at manufacturing facilities can help businesses:
- Reduce electricity costs
- Lower carbon emissions
- Reduce reliance on the National Grid
- Improve energy resilience
- Support ESG and sustainability objectives
- Demonstrate commitment to low-carbon manufacturing
For manufacturers such as J Banks, a well-designed commercial solar PV system provides a practical way to generate renewable energy directly at the point of use while improving long-term operational efficiency.
Looking to Install Commercial Solar?
Energy Gain has extensive experience delivering large-scale commercial rooftop solar installations for manufacturing businesses, industrial facilities, logistics operators and commercial organisations throughout the UK.
Whether your objective is to reduce energy costs, improve sustainability performance or future-proof your manufacturing operations, our engineering team can design a bespoke solar PV solution tailored to your facility.
Contact Energy Gain today for a free feasibility assessment and discover how much your business could save through commercial solar.
