Client Background
Company Name: Manufacturing Company
Location: Leicestershire
Industry: Metal Casting and Manufacturing
Company Overview: This manufacturing company is a medium-sized enterprise specializing in the production of high-quality cast iron products, primarily for the automotive and construction industries. The company has a reputation for precision engineering and durability in its products. With increasing operational costs and a commitment to sustainability, The company sought to reduce its energy expenses and carbon footprint through the adoption of renewable energy solutions.
System Design and Components
To design and implement a 10 kWp solar power system to offset the electrical consumption of the production facility.
System Components:
- Solar Panels: 20 x 500 Wp high-efficiency monocrystalline solar panels
- Inverter: 1 x Rayleigh RI-Energy flow series 10Kw Hybrid Inverter
- Mounting Structure: Custom-engineered mounting structures to support rooftop installation
- Monitoring System: Rayleigh’s smart energy management system for real-time monitoring and performance analysis
Implementation and Challenges
Shading Analysis: A comprehensive shading analysis was conducted to ensure minimal shadowing from nearby structures, resulting in the strategic placement of solar panels for maximum efficiency.
Load Profile: The daily load profile was analysed to ensure the solar system would effectively reduce peak energy demands, particularly during production hours.
Rooftop Installation: The solar panels were securely mounted on the rooftop using custom-engineered structures, ensuring durability and resistance to local weather conditions.
Results and Impact
The 10 kWp solar system is now generating an average of 699 kWh per month, meeting approximately 22% of the facilities total energy needs.
The system has resulted in a reduction of 3.9 tons of CO2 emissions annually, contributing to the company’s sustainability goals.
The system has enhanced the facility’s energy security, particularly during peak production times.
The real-time monitoring system has enabled better energy management and decision-making for Shilton Cast Iron’s operations team.
Conclusion
The implementation of the 10 kWp solar power system in has successfully demonstrated the viability of renewable energy solutions in an industrial setting. Despite the challenges encountered during installation, the project has yielded significant energy savings, reduced carbon emissions, and reinforced the company’s commitment to sustainability.
Moving forward, the company plans to explore other energy-efficient technologies to continue reducing its environmental impact and operational costs. This project serves as a model for other manufacturing companies considering the transition to renewable energy sources.
