Commercial Solar for Manufacturing : Kasai UK Solar PV Case Study
Project Overview
Energy Gain was appointed to design and install a 1.45 MWp commercial rooftop solar PV system at Kasai UK’s manufacturing facility. The project was designed to reduce electricity costs, lower carbon emissions and support the company’s wider sustainability objectives through the use of renewable energy generated on site.
As a leading automotive manufacturing supplier, Kasai UK operates energy-intensive production facilities requiring a reliable and consistent electricity supply. With high daytime energy demand from manufacturing equipment, lighting and building systems, the facility was an ideal candidate for a commercial solar installation for manufacturing.
By generating renewable electricity directly at the point of use, the solar PV system helps Kasai UK reduce reliance on grid electricity, improve energy cost control and support progress towards long-term carbon reduction targets.
The Challenge
Delivering a large-scale solar installation within an operational manufacturing facility required detailed planning, engineering expertise and close coordination with Kasai UK’s production teams.
Maintaining Manufacturing Operations
Manufacturing facilities operate around strict production schedules, meaning installation activities needed to be carefully planned to avoid disruption to daily operations.
The key challenge was delivering the solar PV system safely while allowing manufacturing processes to continue without interruption.
Working Around Industrial Operations
Active manufacturing sites require careful management of vehicle movements, deliveries, contractors and production activities.
Installation works needed to be coordinated around existing operations to maintain safety standards while ensuring the project could progress efficiently.
Maximising Available Roof Space
Large industrial buildings provide significant opportunities for commercial rooftop solar, but each site requires detailed assessment to maximise energy generation.
The system design needed to consider roof suitability, panel positioning, electrical infrastructure and long-term maintenance requirements.
Supporting Sustainability Objectives
Kasai UK required a solar solution that delivered measurable environmental benefits while also providing a strong financial return.
The completed system needed to reduce carbon emissions, improve energy efficiency and support the company’s wider sustainability strategy.
Our Solution
Energy Gain developed a bespoke solar PV solution for manufacturing that maximised renewable energy generation while working around Kasai UK’s operational requirements.
Following detailed site surveys and engineering assessments, our team designed a commercial rooftop solar system that considered available roof space, electrical infrastructure, installation sequencing and future maintenance access.
A carefully planned installation programme allowed works to be completed safely while maintaining normal manufacturing operations. Site access, deliveries and installation activities were coordinated to minimise disruption to production.
The completed solar PV installation enables Kasai UK to generate renewable electricity on site, reducing reliance on imported grid energy and improving long-term control over energy costs.
Engineering Insight
Manufacturing facilities are particularly well suited to commercial solar due to their high daytime electricity demand. Production equipment, machinery, lighting and building systems typically operate during periods when solar generation is at its highest.
Before installation, Energy Gain assessed key engineering requirements including:
- Available roof area and solar generation potential
- Structural suitability of the building
- Electrical infrastructure requirements
- Panel layout optimisation
- Cable routes and inverter locations
- Future maintenance access
Designing a successful industrial solar installation requires more than maximising the number of panels installed. The system must be engineered around the operational requirements of the facility to ensure long-term performance and reliability.
Why Solar is Ideal for Manufacturing Facilities
Manufacturing businesses are among the strongest candidates for commercial solar for manufacturing due to their consistent electricity consumption and large available roof areas.
Factories and industrial facilities often use significant amounts of electricity for machinery, production lines, lighting and ventilation systems. This demand frequently aligns with solar generation periods, allowing businesses to maximise onsite renewable energy use.
Installing solar panels for manufacturing facilities can help businesses:
- Reduce electricity costs
- Lower operational carbon emissions
- Improve energy security
- Support ESG commitments
- Progress towards net-zero targets
- Reduce reliance on grid electricity
For manufacturers, commercial solar provides a practical way to improve sustainability while delivering measurable financial benefits.
Project Results
The completed solar PV system now generates renewable electricity directly on site, reducing both operating costs and carbon emissions while supporting the client’s sustainability objectives.
Project Statistics
- System Size: 1.45 MWp
- Solar Panels Installed: 3411
- Annual Generation: 1059 MWh
- Annual CO₂ Savings: 201 Tonnes
- Lifetime CO₂ Savings: 4723 Tonnes
Looking to Install Commercial Solar?
Energy Gain specialises in delivering commercial solar installations for manufacturing, industrial and commercial organisations across the UK.
From initial feasibility assessments through to design, installation and commissioning, our team helps businesses reduce energy costs, lower carbon emissions and achieve their sustainability objectives.
If your organisation is considering solar panels for a manufacturing facility, contact Energy Gain to understand how much renewable energy your site could generate.
