Archwood Manufacturing Solar Installation Case Study
Project Overview
Energy Gain was appointed to design and install a 945kWp manufacturing solar installation at Archwood’s head office and manufacturing facility in Chirk, North Wales.
Archwood Group is a family-owned manufacturing business specialising in the design, manufacture and supply of timber products for the interiors and home improvement sectors. With significant electricity demand across its manufacturing operations, the business identified solar PV as a key opportunity to reduce energy costs, improve energy resilience and lower carbon emissions.
Following a detailed site energy audit, Energy Gain designed a large-scale solar PV system tailored around Archwood’s operational requirements. The system was commissioned in September 2022 and provides renewable electricity directly to the manufacturing facility, helping reduce reliance on grid electricity and support the company’s sustainability objectives
The Challenge
As with many manufacturing businesses, Archwood required a renewable energy solution that could deliver long-term financial and environmental benefits while working around an active production facility.
High Manufacturing Energy Demand
Manufacturing facilities typically operate energy-intensive equipment throughout the working day, creating significant electricity demand.
Archwood needed a solution that could generate renewable electricity on-site and maximise the amount of solar energy consumed within its own operations.
Maintaining Production Operations
The manufacturing facility remained operational throughout the installation.
Careful planning was required to ensure installation activities, deliveries and contractor access were managed safely without impacting production schedules.
Large-Scale Solar Design
A 945kWp solar system requires detailed engineering to ensure maximum generation while considering:
- Available roof space
- Electrical infrastructure
- Structural requirements
- Panel layout optimisation
- Future maintenance access
The solution needed to provide reliable renewable energy generation for decades while integrating seamlessly with the existing site.
Supporting Sustainability Objectives
Archwood wanted to reduce its environmental impact and improve energy resilience by generating more of its own electricity.
The project supported the company’s wider commitment to reducing carbon emissions and improving operational sustainability.
Our Solution
Energy Gain delivered a complete turnkey manufacturing solar installation, managing the project from initial energy assessment through to design, installation and commissioning.
Before installation began, Energy Gain completed detailed energy profiling to understand Archwood’s electricity consumption and identify the optimum solar PV solution.
The final system design provided a 945kWp solar PV installation specifically configured around the manufacturing facility’s energy requirements.
The installation programme was carefully coordinated with Archwood’s team to minimise disruption to ongoing manufacturing operations.
Our engineers managed all aspects of the project, including:
- Solar PV system design
- Electrical integration
- Installation management
- Health and safety planning
- Commissioning and handover
The completed system now generates renewable electricity directly on-site, helping Archwood reduce electricity costs while lowering its carbon footprint.
Project Results
The completed solar PV system provides Archwood with a reliable source of renewable electricity, helping reduce operational costs and support long-term sustainability goals.
Project Statistics
- System Size: 945kWp
- Number of panels: 2,520
- Annual Generation: 745 MWh
- Lifetime generation: 17,477 MWh
- Annual CO₂ savings: 157 Tonnes
- Lifetime CO₂ Savings: 3,670 tonnes
- Sector: Manufacturing
- Client: Archwood Group
- Location: Chirk, North Wales
- Installation Type: Commercial rooftop solar PV
Engineering Insight
Every manufacturing site presents unique challenges when designing a commercial solar system.
For Archwood, Energy Gain used an engineering-led approach to ensure the system was designed for maximum performance and long-term reliability.
Key considerations included:
• Detailed energy consumption analysis
• Optimised solar panel positioning
• Electrical infrastructure assessment
• Safe installation planning
• Future maintenance requirements
• Maximising on-site renewable energy usage
Large-scale solar installations require more than simply adding panels to a roof. The system must be carefully designed around the building, electrical network and operational requirements of the business.
Why Solar is Ideal for Manufacturing Businesses
Manufacturing facilities are among the strongest candidates for solar PV due to their high daytime electricity consumption.
Factories, production facilities and industrial sites often operate machinery, lighting, ventilation and heating systems during daylight hours when solar generation is highest.
This allows businesses to maximise self-consumption and achieve greater financial benefits from their solar investment.
A manufacturing solar installation can help businesses:
- Reduce electricity costs
- Lower Scope 2 carbon emissions
- Improve energy resilience
- Reduce exposure to energy price increases
- Support sustainability commitments
- Strengthen ESG performance
For manufacturers, generating clean electricity on-site provides both environmental and commercial benefits.
Looking to Install Solar at Your Manufacturing Facility?
Energy Gain specialises in delivering manufacturing solar installations for businesses across the UK.
From factories and industrial facilities to warehouses and commercial buildings, our engineering team designs solar PV systems that reduce energy costs, improve resilience and support long-term sustainability objectives.
If your manufacturing business is considering solar, contact Energy Gain for a free feasibility assessment and discover how much your organisation could save.
