Commercial Solar for Manufacturing | Eurocell 600kWp Solar PV Case Study
Project Overview
Energy Gain was appointed to design and install a 600kWp commercial rooftop solar PV system across two of Eurocell PLC’s largest facilities in the East Midlands. The project was designed to reduce the site’s reliance on grid electricity, lower operational carbon emissions and support Eurocell’s long-term sustainability strategy.
As a leading UK manufacturer, distributor and recycler of PVC-U windows, doors and building products, Eurocell operates energy-intensive facilities requiring significant electricity consumption throughout the working day. This made the sites ideal candidates for solar generation, allowing renewable electricity to be generated directly where it is needed most.
The installation supports Eurocell’s ambition to achieve net-zero emissions by 2045, helping reduce Scope 2 emissions while providing long-term protection against rising energy costs.
The Challenge
Delivering a large-scale solar installation across operational manufacturing facilities requires careful planning, detailed engineering and effective coordination to ensure minimal impact on day-to-day operations.
Maintaining Manufacturing Operations
Manufacturing facilities operate continuously with strict production schedules, vehicle movements and operational requirements that cannot be interrupted.
The key challenge was completing the installation safely while ensuring Eurocell’s manufacturing and distribution activities could continue without disruption.
Large Commercial Roof Areas
Large industrial buildings provide significant opportunities for solar generation but require careful assessment before installation.
The design needed to maximise available roof space while considering factors including structural suitability, panel positioning, cable routes and long-term system performance.
Working Around Active Industrial Sites
Manufacturing environments require strict control of access routes, deliveries, lifting operations and contractor activity.
Installation activities needed to be carefully coordinated around existing site operations to maintain safety for employees, contractors and visitors.
Delivering a System That Supports Long-Term Sustainability Goals
Eurocell required a solar solution that delivered measurable environmental benefits while also providing a strong financial return.
The system needed to maximise onsite renewable energy generation, reduce electricity costs and contribute towards the company’s wider decarbonisation objectives.
Our Solution
Every stage of the project was carefully planned to ensure the solar installation could be delivered safely, efficiently and with minimal disruption.
Energy Gain worked closely with Eurocell’s team to develop a system design that maximised renewable energy generation across the available roof space. Detailed planning considered panel layout, electrical design, installation sequencing and operational requirements.
A comprehensive installation programme was developed to coordinate works around the manufacturing facilities, ensuring access routes remained available and normal operations could continue throughout construction.
The completed system uses 1,364 solar panels to generate renewable electricity directly on-site. By producing electricity at the point of use, Eurocell can reduce reliance on imported grid energy and improve energy cost control.
The project was delivered with a strong focus on safety, quality and long-term reliability, ensuring the system will continue generating clean energy throughout its operational lifetime.
Engineering Insight
Large-scale manufacturing facilities are particularly well suited to commercial solar because electricity demand is typically highest during daylight hours when solar generation is at its peak.
Before installation, Energy Gain considered key engineering factors including:
- Available roof area and system positioning
- Solar generation potential
- Electrical infrastructure requirements
- Cable routing and inverter locations
- Future maintenance access
- Safe installation methodology
Designing a commercial solar system is not simply about installing the maximum number of panels possible. The system must be carefully engineered to balance energy generation, operational requirements and long-term performance.
For industrial facilities such as Eurocell’s sites, maximising onsite consumption is particularly important. Using generated electricity directly within the manufacturing process increases financial savings while reducing dependence on the grid.
Why Solar is Ideal for Manufacturing Facilities
Manufacturing businesses are among the strongest candidates for commercial solar due to their high and consistent electricity demand.
Production equipment, lighting, ventilation systems and machinery often operate throughout normal working hours, aligning closely with solar generation periods.
By generating renewable electricity onsite, manufacturers can:
- Reduce electricity costs
- Lower carbon emissions
- Improve energy security
- Support ESG objectives
- Demonstrate commitment to sustainable manufacturing
Solar also provides businesses with greater control over future energy costs as electricity prices continue to fluctuate.
Project Results
The completed solar PV installation now generates clean electricity directly across Eurocell’s facilities, helping reduce energy costs and support the company’s transition towards net-zero emissions.
The system is expected to generate approximately 532MWh of renewable electricity annually, saving around 112 tonnes of COâ‚‚ emissions every year. Over its lifetime, the installation is forecast to save approximately 2,624 tonnes of COâ‚‚.
System Size: 600kWp
Solar Panels Installed: 1,364
Annual Generation: 532MWh
Annual COâ‚‚ Savings: 112 tonnes
Lifetime COâ‚‚ Savings: 2,624 tonnes
Looking to Install Commercial Solar?
Energy Gain specialises in delivering large-scale 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 commercial solar, contact Energy Gain to understand how much renewable energy your site could generate.
